Torque wrench system having multiple torque stations

ABSTRACT

An improved multi-bolt and nut torque wrench for installing and removing bolts or nuts from flanged joints or the like which includes a plurality of torque stations having a plurality of high torque wrenches for engaging the heads of the bolts or nuts during a high torque phase of removal or installation; a plurality of low-torque motors operatively engaged with the wrenches for rotating the bolts or nuts during the low torque phase of removal or installation; a source of hydraulic fluid for driving the low-torque motors during the low-torque phase, and driving the high-torque wrenches during the high torque phase; and a mechanism for switching between the two phases depending on the torque needed.

CROSS-REFERENCE TO RELATED APPLICATIONS

Priority of U.S. provisional patent application Ser. No. 61/050,067,filed 2 May 2008, is hereby claimed, and such application isincorporated herein be reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A “MICROFICHE APPENDIX”

Not applicable.

BACKGROUND

The present invention relates to torquing systems. More particularly, inone embodiment the present invention relates to an improved torquewrench system having multiple torque stations providing for the makeupand removal of a plurality of threaded bolts or nuts. In one embodimentthe improved torquing system includes both high torque and low torquephases of the makeup or removal process. In one embodiment both highspeed and low speed phases are provided.

In the makeup or break down of large structures, such as, for examplerig risers, the sections of the riser are flanged together with boltsthreadably engaging the flanges on the end of each section, and made upvery tightly to complete the structure. There are numerous other typesof structures which use this same system of makeup, i.e., very largebolts through flanges connecting sections of structures.

Flanged riser joints use specially designed bolts that must be torquedto a precise preload. Typically, flanged riser connectors in theoffshore drilling industry use six (6) bolt flanges with each boltstraddling an auxiliary line position. During the operation of runningthe blow out preventer or “BOP” (e.g., initially installing the BOP andriser), an upper flange of a riser joint in the riser string can belanded and supported on the riser spider (e.g., with the spider dogs inan extended state). A new riser joint can stabbed or placed on top ofthe supported riser joint and the plurality of riser bolts can be turneddown and torqued thereby making up the connection. This process can berepeated as many times as needed until the riser string reaches the seafloor and can be attached to the wellhead.

In a typical rig riser structure the flanged sections of the risersinclude six (6) holes radially spaced apart in about sixty (60) degreeincrements (around the 360 degree bolt circle of the riser sectionflanges). The riser string typically extends from the drilling rig abovethe surface of the water to the wellhead located at sea floor. Indeepwater installations the depth of water typically exceeds 5,000 feet.Riser sections are typically provided in 75 foot lengths, yielding aminimum of 67 riser sections or joints and 67 multiplied by 6 (or 402)bolts which must be properly tightened or made up (when installing theriser) or loosened or broken out (when removing the riser).

Presently, when installing or removing riser sections or joints, torquewrenches are manually positioned and operated to individually tighten orloosen each of the six bolts for each riser section or joint. In aneffort to speed up the process two torque wrenches operated by twooperators can be used addressing two bolts at the same time. However,each operator must individually position and operate his torque wrenchon the head of each bolt when tightening or loosening. The operatorcontinues around the flange until all six bolts have been torqued.Additionally, after completing each bolt, the operator must manuallyremove the torque wrench from the made up bolt and position the torquewrench on the next bolt. After all bolts are torqued down, the spiderdogs are retracted and the riser string (e.g., plurality of riser jointsand BOP) is lowered to allow the placement and make-up of the connectionto the next riser joint section.

This manual process is time consuming and slows down both the initialinstallation along with the removal of the riser. Additionally, theoperators of these torque wrenches can become tired slowing down theprocess, making mistakes, damaging equipment, and/or causing injury. Dueto increasing rig day rates and improved HSE requirements, it isdesirable to create a tool that can preload each riser flange connectionquicker and without human presence at the well center. This wouldimprove rig operational efficiency as well as safety performance. In atypical yearly operation of a drilling rig the riser string can beretrieved (tripping out) and installed (tripping in) between two andtwenty four times.

While certain novel features of this invention shown and described beloware pointed out in the annexed claims, the invention is not intended tobe limited to the details specified, since a person of ordinary skill inthe relevant art will understand that various omissions, modifications,substitutions and changes in the forms and details of the deviceillustrated and in its operation may be made without departing in anyway from the spirit of the present invention. No feature of theinvention is critical or essential unless it is expressly stated asbeing “critical” or “essential.”

BRIEF SUMMARY

One embodiment of the method and apparatus solves the problemsconfronted in the art in a simple and straightforward manner. What isprovided is an improved method and apparatus for robotically andsimultaneously installing or removing a plurality of bolts from theflanged joints of a rig's riser or the like wherein the apparatusincludes a plurality of torque stations each having positionablevariable torque wrenches for engaging the heads of the plurality ofbolts and rotating the bolts during two torque phases including alow-torque phase (which has lower torques but higher rotational speeds),and a high-torque phase (which has higher torques but lower rotationalspeeds).

In one embodiment is provided a plurality of torque wrenches forrotating a plurality of bolts; a positioning mechanism for positioningand removing each wrench on, with, and/or off of the bolts during eachsuccessive cycle of tightening or loosening, and a source of fluid fordriving each torque wrench.

In one embodiment is provided a hydraulically actuated riser spider thatsits on the floor of the drilling rig such as on top of the gimbal orrotary table. In one embodiment the spider will have a wrench systemattached to the spider (which can be welded or bolted on top of thespider).

In one embodiment the wrench system can include a plurality (e.g., sixor eight) torquing stations and their operating systems. In oneembodiment hydraulics to the riser spider and wrench system can comefrom a control panel that is located adjacent or next to the spider andwrench system (e.g., on the drill floor). In one embodiment the controlpanel for the wrench system can be located remote from the torquingstations. In one embodiment the control panel can be located in thedrillers shack.

In one embodiment the wrench system can be placed on the spider and bemoved with the spider to and from the riser. In one embodiment thewrench system can sit on the spider. In one embodiment the wrench systemis connected to (e.g., bolted) to the spider.

In one embodiment operation of the wrench system (and/or spider) willrequire a single individual standing at the control panel, which can bestrategically positioned to observe operation of the tool. In oneembodiment no technicians will be required to be on the wrench systemand/or spider and/or around the riser joint during flange make-up orbreak-out. In one embodiment the control panel for the wrench system canbe located remote from the torquing stations. In one embodiment thecontrol panel can be located in the driller's shack.

In one embodiment the spider can include retractable bearing surfacesthat will hold the upper flange of a riser joint section, and transmitthe weight of the riser string and BOP stack to the gimbal top plate orrotary table.

Makeup

In one embodiment the wrench system can comprise six (6) torque stationswith the ability to preload all six riser bolts simultaneously duringmake-up. In one embodiment each torque station will torque each riserbolt to substantially the same torque value. In one embodiment each boltwill be torqued to within an acceptable range of a specified make-uptorque value. In one embodiment the acceptable range is within about 1,2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21,22, 23, 24 and/or 25 percent of each other. In various embodiments theacceptable range is between about any two of the above specifiedpercentages.

In one embodiment a record (which can be computer generated) can be keptfor the makeup value of each bolt in the riser string.

In one embodiment the make up sequence for each riser joint can includethe following steps: (a) extending the spider legs (which can becontrolled by the control panel) to support a riser string; (b) loweringthe riser string until the top flange lands on spider dogs; (c)activating the torquing sequence of the wrench system from the controlpanel; (d) having the plurality of torquing stations engaging theirrespective bolts; (e) having the plurality of torquing stations spinningdown their respective bolts from the lower flange on the upper risersection to the upper flange on the lower riser section; (f) having theplurality of torquing stations torquing down their respective bolts to adesired torque or torque range; (g) having the plurality of torquingstations disengaging the plurality of bolts and providing clearance forthe riser string to be lowered, supported by the spider, and a new riserjoint to be stabbed on top of the riser string; (h) lowering the made upportion of the riser string and stabbing a new riser joint on top of thelowered riser string; and (i) extending the spider legs to support theriser string.

In one embodiment the during step “d” the plurality of torquing stationsmove from retracted positions to radially extended positions. In oneembodiment the plurality of torquing stations in step “d” move fromupper positions to lower positions. In one embodiment the move fromretracted to radially extended positions occurs before the move fromupper positions to lower positions.

In one embodiment steps “c” through “g” are completed within less than aset period of time. In one embodiment the set period of time is lessthan 5, 4.5, 4, 3.5, 3, 2.5, 2, 1.5, and 1 minutes. In variousembodiments the set period of time is between any two of the abovespecified periods of time.

In one embodiment when first radially extended the upper part of thetorque wrench is located within a projected circle of a flotation unitattached to the upper riser section, but also located between thefloatation unit and the head of the bolt. In this way the torque wrenchclears the floatation attachment without damaging same.

In one embodiment in step “d” the plurality of torquing stationssimultaneously first engage the plurality of bolts. In one embodiment instep “d” at least of the plurality of torquing stations first engage theplurality of bolts at a different time then at least one of the other ofthe plurality of torquing stations.

In one embodiment during step “e” each bolt can freely vertically dropbetween the threads of the upper flange section and lower flange sectionof the two riser sections being attached. In one embodiment during thisfree drop the head of the bolt can remain engaged with the drive socket.In one embodiment the rotational speed of the drive socket can remainconstant during the free drop of the bolt. In one embodiment thevertical speed of the drive socket can remain constant during the freedrop.

In one embodiment during step “e” the spinning down can include a highspeed/low torque rotation of the bolts, and during step “f” the torquingdown can include a low speed/high torque rotation of the bolts, wherehigh torque is substantially higher than low torque, and high speed issubstantially higher than low speed.

In one embodiment step “e” can include first and second rotational highspeeds, where the second rotational high speed is higher than the firstrotational high speed, and both first and second rotational high speedsare substantially higher than the low speed of step “f.” In oneembodiment the first rotational high speed is 15, 20, 25, 30, 35, 40,45, 50, 55, 60, 65, 70, and/or 75 percent of the second rotational highspeed. In various embodiments the first rotational high speed is betweenabout any two of the above specified percentages in relation to thesecond rotational high speed.

In one embodiment the rate of vertical speed of the drive socket head ofeach torquing station changes with the rotational speed of the drivesocket. In one embodiment the rate of vertical speed of the drive socketis synchronized with the rotational speed of the drive socket. In oneembodiment step “e” can include first and second vertical high speeds,where the second vertical high speed is higher than the first highspeed, and both first and second vertical high speeds are substantiallyhigher than the low vertical speed of step “f.” In one embodiment thefirst vertical high speed is 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65,70, and/or 75 percent of the second vertical high speed. In variousembodiments the first vertical high speed is between about any two ofthe above specified percentages in relation to the second vertical highspeed.

In one embodiment first and second rotational high speeds of step “e”can be switched based on the height of the drive socket of each torquingstation. In one embodiment first and second rotational high speeds ofstep “e” can be switched based on the height of the bolt being spundown. In one embodiment the switch can be based on the bolt engaging atleast two threads of in the lower flange of the two sections of riserjoints being attached. In one embodiment the switch from first to secondhigh speeds can occur simultaneously with a plurality of torquingstations (or with all torquing stations). In one embodiment there can bea pause between the switch from first to second rotational high speedsof all torquing stations. In various embodiments the pause can be ½, ¾,1, 1½, 2, 3, 4, and 5 seconds. In various embodiments the pause can bebetween any two of the above specified time periods.

In one embodiment the switch from step “e” to step “f” can be switchedbased on the height of the drive socket of each torquing station. In oneembodiment the switch from step “e” to step “f” can be based on theheight of the bolt being spun down. In one embodiment the switch can bebased on the shoulder of the bolt engaging the upper flange of the twosections of riser joints being attached. In one embodiment the switchfrom step “e” to step “f” can occur simultaneously with a plurality oftorquing stations (or with all torquing stations). In one embodimentthere can be a pause between the switch from step “e” to step “f” forall torquing stations. In various embodiments the pause can be ½, ¾, 1,1½, 2, 3, 4, and 5 seconds. In various embodiments the pause can bebetween any two of the above specified time periods. In one embodimentduring the pause the rotational control of the drive sockets are relaxedso as not to attempt to rotate the bolts. In one embodiment the verticallocation controls of the drive sockets are relaxed. In one embodimentthe radial positioning controls are relaxed.

In one embodiment step “f” can simultaneously start with a plurality oftorquing stations (or with all torquing stations). In one embodimentstep “f” can simultaneously start with one half of the torquing stations(e.g., torquing stations 110A-C) and then simultaneously start thesecond half of the torquing stations (e.g., stations 110D-F). In oneembodiment step “f” can simultaneously start with two of the torquingstations (e.g., torquing stations 110A-B), and then simultaneously startwith a second two of the torquing stations (e.g., stations 110C-D), andthen simultaneously start with a third two of the torquing stations(e.g., stations 110E-F).

In one embodiment each of the torquing stations can continue in step “f”until the individual torquing station reaches a desired make up torquefor its respective bolt. In one embodiment the desired make-up torquecan be based on the stalling hydraulic pressure sent to the low speedhigh torque system of the particular torquing station.

In one embodiment the switch from step “f” to step “g” can occursimultaneously for each of the torquing stations. In one embodiment theswitch from step “f” to step “g” can occur simultaneously for aplurality of the torquing stations. In one embodiment the switch fromstep “f” to step “g” can occur separately for each of the torquingstations, and can be based on the individual torquing stations torquingup its respective bolt to the desired torque.

In one embodiment, a warning signal is sent if one or more torquingstations are not able to torque up its respective bolt to a desiredtorque. In one embodiment this warning signal is sent after a set periodof time after the particular torquing station entered high torque mode(i.e., step “f”).

In one embodiment the during step “f” the plurality of torquing stationsmove from extended positions to radially retracted positions. In oneembodiment the plurality of torquing stations in step “f” move fromlower positions to upper positions. In one embodiment the move fromlower to upper positions occurs before the move from radially extendedto radially retracted positions. In one embodiment, after raising aspecified vertical height both radial retraction and raising of thedrive socket can occur at a torquing stations. In one embodiment the setheight is based on adequately clearing the station's respective head ofits made up bolt.

In one embodiment during step “h” the riser string can be supported bythe draw works of the rig or the top drive of the rig.

In one embodiment steps “a” through “i” are repeated until enough riserjoints or sections are connected to the riser string so that the stringcan be attached to a well head.

Break-Out

In one embodiment the break out (or riser retrieval) sequence for eachriser joint can include the following steps: (a) extending the spiderlegs/dogs (which can be controlled by the control panel) to support ariser string; (b) raising the riser string until an upper flange landson spider dogs; (c) activating the torquing sequence of the wrenchsystem from the control panel; (d) having the plurality of torquestations engaging their respective bolts; (e) having the plurality oftorque stations breaking out their respective bolts from the upperflange on the lower riser section to the lower flange on the upper risersection; (f) having the plurality of torque stations spinning up boltsfrom the lower flange; (g) having plurality of torque stations liftingtheir respective bolts to the upper flange; (h) having the plurality oftorque stations spinning their respective bolts into a storage positionon the upper flange; (i) having the plurality of torque stationsdisengaging the plurality of bolts and providing clearance for the riserstring to be raised; (j) retrieving the disconnected riser section; (k)raising the remaining portion of the riser string; and (l) extending thespider legs/dogs and supporting the remaining portion on the spiderlegs/dogs.

In one embodiment the during step “d” the plurality of torquing stationsmove from retracted positions to radially extended positions. In oneembodiment the plurality of torquing stations in step “d” move fromupper positions to lower positions. In one embodiment the move fromretracted to radially extended positions occurs before the move fromupper positions to lower positions. In one embodiment, for at least aportion of step “d” the move vertical and radial movement occursimultaneously.

In one embodiment steps “c” through “i” are completed within less than aset period of time. In one embodiment the set period of time is lessthan 5, 4.5, 4, 3.5, 3, 2.5, 2, 1.5, and 1 minutes. In variousembodiments the set period of time is between any two of the abovespecified periods of time.

In one embodiment when radially extended the upper part of the torquewrench is located within a projected circle of a flotation unit attachedto the upper riser section, but also located between the floatation unitand the head of the bolt. In this way the torque wrench clears thefloatation attachment without damaging same.

In one embodiment in step “d” the plurality of torquing stationssimultaneously first engage the plurality of bolts. In one embodiment instep “d” at least of the plurality of torquing stations first engage theplurality of bolts at a different time then at least one of the other ofthe plurality of torquing stations.

In one embodiment, during step “d” each of the drive sockets at theirrespective torquing stations can rotate at a first high rotational speeduntil dropping down to a first vertical height as determined by a heightsensor. In one embodiment a first vertical height of the socket headcorresponds to the drive socket being located on the bolt head.

In one embodiment each drive socket is rotated at the first rotationalspeed until the drive socket reaches a second vertical height at whichtime the high speed low torque motor is stopped and hydraulicallyrelaxed. At this same time vertical movement of the drive socket head isstopped and the hydraulic motor driving the vertical positioning screwis hydraulically relaxed for a set period of time. In one embodiment theset period of time can be ½, ¾, 1, 1½, 2, 3, 4, and 5 seconds. Invarious embodiments the set period of time can be within a range ofbetween any two of the above set periods of time.

In one embodiment steps “d” and “f” can include first and secondrotational high speeds, where the second rotational high speed is higherthan the first rotational high speed, and both first and secondrotational high speeds are substantially higher than the low speed ofstep “e.” In one embodiment the first rotational high speed is 15, 20,25, 30, 35, 40, 45, 50, 55, 60, 65, 70, and/or 75 percent of the secondrotational high speed. In various embodiments the first rotational highspeed is between about any two of the above specified percentages inrelation to the second rotational high speed.

In one embodiment if a first vertical height of drive socket is notachieved within a set period of time at a particular torquing station,at least one locating high torque stroke is made on the drive socket toassist in locating the drive socket on the bolt head and a further checkon the vertical height of the socket head is made to determineengagement of the bolt head by the drive socket. In one embodiment afterthe first iteration of the locating drive stroke is made and thelocating high torque stroke is not achieved for the drive socket, asecond iteration of locating drive stoke is made and the vertical heightof the drive socket is checked. In various embodiment multipleiterations of locating high torque strokes can be made along with checksof the vertical heights of the drive sockets, until engagement of thebolt head is determined.

In various embodiments, before each locating high torque stroke is made,vertical movement of the drive socket is stopped. In one embodiment thevertical control system is also relaxed before each locating high torquestroke is made.

In various embodiments, before each locating high torque stroke is made,rotation of the drive socket is stopped. In one embodiment the highspeed rotational motor is also relaxed before each locating high torquestroke is made. In one embodiment pressure is maintained on therotational motor to assist in positioning each drive socket after it haslocated the head of its particular riser bolt.

In various embodiments, before each locating high torque stroke is made,the radial positioning system for the drive socket is relaxed.

In one embodiment, a warning signal is sent if one or more torquingstations are not able to be located on their respective bolt head withina set period of time (i.e., step “d”), or within a set number of hightorque locating strokes.

In one embodiment, after reaching the first vertical height, thevertical positioning screw moves the drive socket to a second verticalheight and holds the drive socket at this height. In one embodiment atthe time the vertical positioning screw is stopped, the drive sockethead enters a high torque break-out mode (step “e”).

In one embodiment during the high torque break out mode (step “e”), thehigh torque cylinder is cycled for a set number of cycles. In oneembodiment the set number of cycles can be 1, 2, 3, 4, 5, 6, 7, 8, 9,10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 30, 35,40, 45, and 50. In various embodiments the set number of cycles can bewithin a range of between any two of the above set number of cycles. Inone embodiment after its last cycle, the high torque system fullyretracts. In one embodiment full retraction is determined by a timingsequence using the high torque hydraulic cylinder, such as extensionhydraulic pressure for a set period of time which can be ½, ¾, 1, 1½, 2,3, 4, and 5 seconds. In various embodiments the set period of time canbe within a range of between any two of the above set periods of time.

In one embodiment each of the drive sockets are started in the hightorque mode simultaneously (step “e”). In one embodiment step “e” cansimultaneously start with a plurality of torquing stations (or with alltorquing stations). In one embodiment step “e” can simultaneously startwith one half of the torquing stations (e.g., torquing stations 110A-C)and then simultaneously start the second half of the torquing stations(e.g., stations 110D-F). In one embodiment step “e” can simultaneouslystart with two of the torquing stations (e.g., torquing stations110A-B), and then simultaneously start with a second two of the torquingstations (e.g., stations 110C-D), and then simultaneously start with athird two of the torquing stations (e.g., stations 110E-F).

In one embodiment each of the torquing stations can continue in step “e”until the individual torquing station reaches a desired rotation of therespective bolt being broken out. In one embodiment the desired turn canbe based on a number of strokes of the high torque system.

In one embodiment during the high torque mode the drive socket is notmoved vertically upward. In this embodiment vertical movement of thedrive head is taken up by a vertical angular turning of the torquewrench body. In one embodiment this differential vertical angularturning of the torque wrench body is relieved when the bolt leaves thethreads of the lower flange, and is located in the gap between the upperand lower flanges, and is being raised by the lifting fork. In oneembodiment the arms of the lifting fork are about set distance below thetip of the drive socket. In one embodiment the set distance is ¼, ⅜, ½,⅝, ¾, ⅞, 1, 1¼, 1⅜, 1½, 1⅝, 1¾, 1⅞, 2 inches. In various embodiments theset distance can be within a range of between any two of the abovespecified distances.

In one embodiment the high torque mode is switched to low torque modeafter a specified lower back pressure is achieved on the high torquesystem. In one embodiment a check can be made on the low torque highspeed to see if it stalls when breaking out the bolt. In one embodimentthe stalling condition is determined based on reaching a specified backpressure for the motor. In one embodiment the stalling condition isdetermined upon falling below a specified flow rate through the motor.

In one embodiment the switch from high torque to low torque modes foreach of the modules are done simultaneously.

In one embodiment the rate of vertical movement of each drive sockethead remains constant during vertical lifting of the drive socketsduring break out. In one embodiment the rotational speed of the drivesocket head remains constant during vertical lifting.

In one embodiment at a set vertical height the lifting fork is extended.In one embodiment full extension of the lifting fork is determined by atiming sequence using the lifting fork hydraulic cylinder(s), such asextension hydraulic pressure for a set period of time which can be ½, ¾,1, 1½, 2, 3, 4, and 5 seconds. In various embodiments the set period oftime can be within a range of between any two of the above set periodsof time.

In one embodiment the lifting fork remains extended until the drivesocket head reaches a second vertical height at which height the liftingfork is retracted. In one embodiment full retraction of the lifting forkis determined by a timing sequence using the lifting fork hydrauliccylinder(s), such as by retraction hydraulic pressure for a set periodof time which can be ½, ¾, 1, 1½, 2, 3, 4, and 5 seconds. In variousembodiments the set period of time can be within a range of between anytwo of the above set periods of time.

In one embodiment rotation of the drive socket is stopped simultaneouslywith the start of retraction of the lifting fork.

In one embodiment after start of retraction of the lifting fork, thedrive socket is sent to a home position for retracted vertical andretracted horizontal positioning.

In one embodiment the retracted vertical mode is achieved before thestart of retraction in a horizontal mode. In one embodiment the drivesocket is not spun either in high speed or in high torque duringretraction. In one embodiment retraction vertically is checked by avertical height sensor. In one embodiment retraction horizontally is bya pre-set time period. The horizontal radially retracted home positioncan be checked by a timing sequence using the body slide cylinders, suchas retraction hydraulic pressure for a set period of time which can be1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 seconds of retraction pressure. Invarious embodiments the set period of time can be within a range ofbetween any two of the above set periods of time. Fully retractedpositions can be controlled by fully retracted body slide cylinders, orby a retraction catch, or a combination of the two. In one embodimentthere can be an adjustable body retraction stop for each body module inthe retraction step.

In one embodiment the rate of vertical speed of the drive socket head ofeach torquing station changes with the rotational speed of the drivesocket. In one embodiment the rate of vertical speed of the drive socketis synchronized with the rotational speed of the drive socket.

In one embodiment the during step “i” the plurality of torquing stationsmove from extended positions to radially retracted positions. In oneembodiment the plurality of torquing stations in step “i” move fromlower positions to upper positions. In one embodiment the move fromlower to upper positions occurs before the move from radially extendedto radially retracted positions. In one embodiment, after raising aspecified vertical height both radial retraction and raising of thedrive socket can occur at each torquing stations. In one embodiment theset height is based on adequately clearing the station's respective headof its broken out bolt.

In one embodiment during steps “j” and “k” the broken out riser flangeis removed, and the riser is raised until a new flange is revealed to bebroken out. In one embodiment the above specified steps are repeated fornewly revealed flange connection.

In one embodiment the above specified steps are repeated until thelength of riser has been removed.

In one embodiment during step “k” the riser string can be supported bythe draw works of the rig or the top drive of the rig.

In one embodiment steps “a” through “l” are repeated until the entireriser is retrieved.

General Operation

Multiple Bolts Simultaneously

In one embodiment the method includes simultaneously tightening (makingup) or loosening (breaking out) a plurality of bolts.

In one embodiment a plurality of at least 3, 4, 5, and/or 6 bolts aresimultaneously tightened or loosened.

In one embodiment is provided a plurality of independently operatedtorque drivers. In one embodiment a plurality of at least 3, 4, 5, or 6torque drivers are provided.

In one embodiment the plurality of bolts are in a bolt circle. In oneembodiment the plurality of bolts are symmetrically and radially spacedapart by about 60 degrees each.

In one embodiment the plurality of bolts will or have connected tworiser sections or joints of a riser string.

In one embodiment a plurality of drivers are provided each individuallypositionable both generally laterally and/or vertically.

In one embodiment a plurality of at least 3, 4, 5, and/or 6 drivers arepositionable together to tighten (make up) or loosen (break out)respective bolts.

Method Steps at Individual Torque Stations

In one embodiment the method includes the driver moving verticallyupward or downward when the bolt is being loosened or tightened.

In one embodiment a visual check is made of the existence and/orposition of each bolt to be tightened (make up) or loosened (break out).If the visual check is satisfied the making up or breaking out sequencescan begin.

Tightening (or Making Up)

In one embodiment a second section of riser is positioned next to afirst section of riser, the second section of riser including aplurality of bolts.

In one embodiment a plurality of drivers are moved horizontally closerto a respective plurality of bolts to be tightened (made up).

In one embodiment a plurality of drivers are moved vertically closer tothe respective plurality of bolts to be tightened (made up).

In one embodiment a plurality of drivers are turned to tighten therespective plurality of bolts to be tightened (made up).

In one embodiment a plurality of high speed/low torque systems controlthe turning of the respective plurality of bolts to be tightened. In oneembodiment control can be switched between high and low torque systemsas many times as needed or desired.

In one embodiment a plurality of low speed/high torque systems cantransition to control over the turning of the respective plurality ofbolts to be tightened. In one embodiment control can be switched betweenhigh and low torque systems as many times as needed or desired.

In one embodiment a plurality of drivers are moved vertically downwardwith the respective plurality of bolts to be tightened (made up) as thebolts move downward.

In one embodiment a plurality of drivers are moved vertically downwardat a different vertical speeds with the respective plurality of bolts tobe tightened (made up) as the bolts move downward.

In one embodiment each driver can be independently controlled in bothcontrolling driver (high or low speed), and speed of vertical movement.

In one embodiment the first and second sections of risers are loweredand a third riser joint or section is positioned next to the secondriser joint or section, and the third riser joint or section including aplurality of bolts to be made up.

In one embodiment the above tightening steps are repeated until a riserstring spans from adjacent the sea floor (e.g., wellhead or blow outpreventers) to the rig or platform.

In one embodiment the method includes the step of allowing a bolt todrop a distance while the bolt head is still retained in the driver. Inone embodiment multiple bolts are allowed to drop a distance.

In one embodiment, after each of the plurality of bolts have been spundown so that shoulder to shoulder contact exists, each torque stationsimultaneously begins the final high torque makeup of their respectivebolts. Simultaneously performing the final high torque make-up isbelieved to provide a more uniform make up connection between the risersections or joints (e.g., keeping the flanges of the riser joints orsection more parallel).

In one embodiment, at each torque station, the tightening cycle for eachbolt is stopped after a desired torque on the bolt is reached (e.g., thehigh torque driver system stalls based on supply pressure), and thedriving system is removed from the bolt.

In one embodiment the method includes the driver moving verticallydownward when the bolt is being tightened.

In one embodiment, the retraction and disengagement of the drivingsystem at each torque station includes the step of raising the driver sothat it can at least clear the bolt head and moving away the driverradially from the bolt.

In one embodiment the vertical height of the system is limited toprevent the system from damaging the floatation/insulation found on eachriser section or joint.

Loosening (or Breaking Out)

In one embodiment a plurality of drivers are moved horizontally closerto a respective plurality of bolts to be loosened (broken out) fromsecond and first sections of riser.

In one embodiment a plurality of drivers are moved vertically closer tothe respective plurality of bolts to be loosened (broken out).

In one embodiment a plurality of drivers are turned to loosen therespective plurality of bolts to be loosened (broken out).

In one embodiment a plurality of high speed/low torque systems controlthe turning of the respective plurality of bolts to be loosened. In oneembodiment control can be switched between high and low torque systemsas many times as needed or desired.

In one embodiment a plurality of low speed/high torque systems cantransition to control over the turning of the respective plurality ofbolts to be loosened. In one embodiment control can be switched betweenhigh and low torque systems as many times as needed or desired.

In one embodiment a plurality of drivers are moved vertically upwardwith the respective plurality of bolts to be loosened (broken out) asthe bolts move upward.

In one embodiment a plurality of drivers are moved vertically upward ata different vertical speeds with the respective plurality of bolts to beloosened (broken) as the bolts move upward.

In one embodiment each driver can be independently controlled in bothcontrolling driver (high or low speed), and speed of vertical movement.

In one embodiment the method includes the step of using a fork to lift abolt to a vertical distance while the bolt head is still retained in thedriver.

In one embodiment the driving cycle of each bolt is stopped after adesired height of the bolt is reached (e.g., the head of the boltreaches a specified storage height), and the driving system isdisengaged from the bolt.

In one embodiment the first riser section or joint is retrieved, and theremaining riser string is raised to reveal another riser section orjoint to be retrieved, along with another plurality of bolts to beloosened.

In one embodiment the above retrieval steps are repeated until eachriser section or joint in the riser string is retrieved.

In one embodiment the removal of the driving system includes the step ofraising the driver so that it can at least clear the bolt head andmoving away the drive radially from the bolt.

In one embodiment the method includes the driver moving verticallyupward when the bolt is being loosened.

In one embodiment, at each torque station, the loosening cycle for eachbolt is stopped after a desired height for the bolt is reached (e.g., aspecified storage height for the bolt), and the driving system isdisengaged and retracted from the bolt for the next loosening cycle.

In one embodiment, the retraction and disengagement of the drivingsystem at each torque station includes the step of raising the driver sothat it can at least clear the bolt head and move away the driverradially from the bolt.

In one embodiment the vertical height of the system is limited toprevent the system from damaging the floatation/insulation found on eachriser section or joint.

Type of Control

In one embodiment a plurality of torque drivers are roboticallycontrolled. In one embodiment a plurality of at least 3, 4, 5, and/ortorque drivers are controlled. In one embodiment the control issimultaneous.

In one embodiment a plurality of torque drivers are computer controlled.In one embodiment a plurality of at least 3, 4, 5, and/or torque driversare controlled. In one embodiment the control is simultaneous.

In one embodiment a plurality of torque drivers are automaticallycontrolled. In one embodiment a plurality of at least 3, 4, 5, and/ortorque drivers are controlled. In one embodiment the control issimultaneous.

In one embodiment a plurality of torque drivers are remotely controlled.In one embodiment a plurality of at least 3, 4, 5, and/or torque driversare controlled. In one embodiment the control is simultaneous.

Items which are Controlled

Position of Driver

In one embodiment the control includes controlling the position of thedriver. In one embodiment each of the plurality of torque drivers arepositionable laterally (or radially towards or away from its respectivebolt) and/or vertically (toward or away from its respective bolt).

In one embodiment each torque driver has a controlled vertical downwardmotion when tightening (making) up bolt. In one embodiment thecontrolled vertical motion of the driver is performed by a lifting andlower mechanism.

In one embodiment the lifting and lowering mechanism approximates thevertical movement of the bolt being tightened or loosened. In oneembodiment each torque driver can move vertically substantially same asbolt which is engaged by the torque driver.

In one embodiment the vertical distance moved by the bolt isapproximated by calculating the number of turns of the bolt and thepitch of the threads for the bolt. In this manner the vertical movementcan be calculated by multiplying the number of turns of the bolt by thepitch. In one embodiment, at each torque station, the vertical speed ofthe driver is slightly greater than the vertical speed of the bolt beingtightened, and motor controlling vertical movement of the driver stallswhen it overshoots the vertical distance traveled by the bolt, andrestarts when the bolt again moves ahead of the driver. In this mannerthe driver can be continuously maintained on the head of the bolt duringtightening.

In one embodiment, at each torque station, the vertical speed of thedriver is slightly lower than the vertical speed of the bolt beinglowered, and motor controlling vertical movement of the driver can bespeeded up when the bolt overshoots the vertical distance traveled bythe driver. In this manner the driver can be continuously maintained onthe head of the bolt during loosening.

In one embodiment the driver is slidingly connected to rig floor suchthat it can move in a substantially horizontal direction. In oneembodiment a track system is used to guide movement of the driver. Inone embodiment a linear bear or rod and bushing system is used.

Rotational Speed and Torque on Driver

In one embodiment at each torque station is provided torque drivers withboth a high torque driving system and a low torque driving system. Inone embodiment the low torque driving system drives at a fasterrotational speed compared to the high torque driving system. In oneembodiment both high torque driving system and low torque driving systemare operatively connected to same driver for bolt.

In one embodiment the low torque driver system can have a plurality ofdriving speeds (such as fast, medium, and slow speeds), where theplurality of speeds are faster than the driving speed of the high torquedriving system.

In one embodiment the both the high speed/low torque system and lowspeed high torque system are simultaneously operatively connected to thedriver. In this vein when the high speed/low torque assembly isoperating the driver, the low speed/high torque system will not inhibitmovement of the driver because of a reverse ratcheting effect.Similarly, when the low speed/high torque system controls the driver(e.g., the high speed/low torque motor has stalled or been set to anon-energized state), the high speed/low torque system allows operationof the low speed/high torque assembly by turning along with the driverbeing turned by the low speed/high torque assembly.

In one embodiment each wrench includes a high speed/low torque motorcontrolling the high speed/low torque phase.

In one embodiment the rotational speed of the high speed/low torquedriver is about 100 revolutions per minute. In one embodiment the highspeed driver can have a programmable lower speeds such as 5 or 10percent of the max speed.

In one embodiment each wrench includes a low speed/high speed torquewrench controlling the low speed/high torque phase.

In one embodiment one or more of the wrenches include mechanisms forautomatically switching between the high speed/low torque phases and thelow speed/high torque phases based on the individual torque requirementsof the plurality of bolts being tightened or loosened.

Both Systems Energized Simultaneously

In one embodiment, both the high speed/low torque system can beenergized simultaneously with the low speed/high torque system (becauseneither driving system in a non-operating state, or in a reducedoperating state, will not interfere with the other driving assembly inthe operating state).

In this embodiment switchover between the two systems depends on whichsystem is controlling rotation of the bolt at any given instant.

In one embodiment both high and low torque drivers continue forsubstantially all of the processes when tightening (making up) orloosening (breaking out) a plurality of bolts.

Switchover by Height

In one embodiment transition between the high torque driver and lowtorque driver occurs when height of driver reaches a predeterminedposition.

In one embodiment both high and low torque drivers continue forpredetermined amounts of process for (making up) or loosening (breakingout) a plurality of bolts.

In one embodiment the predetermined amount for continuance of high withlow is one predetermined amount and the predetermined amount forcontinuance of low with high is a second predetermined amount.

Switchover by Pressure

In one embodiment the back pressure of the high speed/low torque motorcan be sensed to determine a switchover point to the low speed/hightorque system. This is a switchover can be made when the high speed/lowtorque motor is determined to be in a stalled condition.

In one embodiment the back pressure of the low speed/high torqueassembly can be sensed to determine a switchover point to the highspeed/low torque system. This is a switchover can be made when the backpressure in the low speed/high torque system is determined to be below aspecified minimum pressure. In one embodiment the high speed low torquesystem can be energized/pressurized (but in a stalled condition) evenwhen the low speed/high torque system is controlling the driver, but thelow speed/high torque system is set to non-energized condition when itis determined that the high speed/low torque motor is no longer in astalled condition (e.g., the back pressure from the high speed/lowtorque motor drops below a specified stalled pressure).

In one embodiment the stalling of the high speed/low torque motor in aparticular wrench of the plurality of wrenches causes a transition tothe low speed/high torque phase for such particular wrench.

In one embodiment falling below a specified resistance torque on the lowspeed/high torque wrench causes a transition to the high speed/lowtorque phase.

Structure of Wrenches

In one embodiment, at each torque station, the torque driver cancomprise:

-   -   a body having a high torque wrench assembly, the high torque        assembly being operatively connected to a main driver;    -   a high torque wrench assembly, the high torque assembly being        operatively connected to the main driver and rotating the main        driver; and    -   the driver being adjustable both in lateral and vertical        directions, the lateral direction being substantially        perpendicular to the vertical direction.

In one embodiment each torque driver includes a low torque assembly, thelow torque assembly being operatively connected to the main driver androtating the main driver, wherein the maximum torque of the low torqueassembly is less than the maximum torque of the high torque assembly andthe speed of the low torque assembly is greater than the speed of thehigh torque assembly.

One Way/Two Way Torque Wrench

In one embodiment a plurality of one way high torque wrench drivers areused.

In one embodiment to switch from tightening for (making up) or loosening(breaking out) body of toque wrench can be flipped.

In one embodiment a plurality of two way torque wrenches are used toavoid the necessity of turning the plurality of torque wrench bodiesbetween loosening and tightening modes.

Fork Lift for Lifting Bolt During Loosening (or Breakout)

In one embodiment a bolt lifting mechanism is operatively connected toeach driver.

In one embodiment the bolt lifting mechanism is slidingly connected tobody of torque wrench.

In one embodiment the bolt lifting mechanism is controlled through apiston, or through a plurality of pistons.

In one embodiment the bolt lifting mechanism vertically travels withbody of torque wrench.

In one embodiment the bolt lifting mechanism is a fork

Final Torque

In one embodiment a check is made regarding the final torque on eachbolt (e.g., 32A-F) during the tightening process. Such final torque canbe calculated based on the back pressure (e.g., the stalling or backpressure of the hydraulic piston 740) during the high torque phase. Inone embodiment a check is made against a minimum torque (such as by acalculation of the torque from the stalling or back pressure) and if theminimum torque is not achieved on one or more of the pistons 740A-F andcylinders 700A-F a warning signal is made. In one embodiment a record iskept of the torquing on each bolt during the make up (and/or break outprocedure) for a substantial portion (or the entire riser).

In one embodiment a maximum of 40,000 foot pounds of torque can beobtained. In one embodiment the final torque of the driver is about18,000 foot pounds.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

For a further understanding of the nature, objects, and advantages ofthe present invention, reference should be had to the following detaileddescription, read in conjunction with the following drawings, whereinlike reference numerals denote like elements and wherein:

FIG. 1 is a top view of the rig floor with the spider dogs in anextended state supporting the riser string with the upper flange of ariser joint exposed.

FIG. 2 is a perspective and sectional view of the spider showing thespider dogs in an extended state.

FIGS. 3 through 10 show various sequence steps in a make up process forone of the torque stations.

FIG. 3 is a top view showing one embodiment of the torque wrench systemduring make up with all six of the torque stations (110A-F) inhorizontally retracted states (and station 110A in a partially brokenout view).

FIG. 4 is a top view showing one embodiment of the torque wrench systemduring make up with all six of the torque stations (110A-F) inhorizontally extended states (and station 110A in a partially broken outview).

FIG. 5A is a schematic side view one of the torque stations ready forthe beginning of a make up or break out sequence as the driver socket iscompletely retracted horizontally and moved to its highest verticalposition which will clear a bolt previously placed in a storagecondition for a riser joint along with being below the lowest point ofthe insulation or floatation for the upper riser section or joint. FIG.5B is a top view of the torque station of FIG. 5A shown in partiallybroken out view.

FIG. 6A is a schematic side view the torque station of FIG. 5 where thedriver socket has moved horizontally over a bolt and is rotating fortightening, the driver socket is also moving downwardly, and is about toengage the bolt head. FIG. 6B is a top view of the torque station ofFIG. 6A shown in partially broken out view.

FIG. 7A is a schematic side view of the torque station of FIG. 5 wheredriver socket has engaged the bolt and begun to spin down the boltthrough the upper flange and into the gap. FIG. 7B is a top view of thetorque station of FIG. 7A shown in partially broken out view.

FIG. 8A is a schematic side view of the torque station of FIG. 5 afterthe driver socket has spun down the bolt, and the bolt is now allowed afree fall through the gap between the flanges, and the head of the bolthas vertically dropped in relation to the drive socket. FIG. 8B is a topview of the torque station of FIG. 8A shown in partially broken outview.

FIG. 9A is a schematic side view of the torque station of FIG. 5 afterthe driver socket has spun down the bolt, allowed a free fall of thebolt through the gap between the flanges, and spun down the bolt to thelower flange by about two threads in the lower flange. FIG. 9B is a topview of the torque station of FIG. 9A shown in partially broken outview.

FIG. 10A is a schematic side view of the torque station of FIG. 5 afterthe driver socket has spun down the bolt until shoulder to shouldercontact between the upper flange and the bolt head has occurred, and thetorque station to go into a high torque mode where the piston and drivegear controls rotation of the driver. After the desired make up torqueis achieved the driver socket will be moved upward and retracted to theposition shown in FIG. 5 and be ready for the next make up cycle. FIG.10B is a top view of the torque station of FIG. 10A shown in partiallybroken out view.

FIGS. 11 through 21 show various sequence steps in a break out processfor one of the torque stations.

FIG. 11 is a top view showing one embodiment of the torque wrench systemduring break out with all six of the torque stations (110A-F) inhorizontally retracted states (and station 110A in a partially brokenout view).

FIG. 12 is a top view showing one embodiment of the torque wrench systemduring break out with all six of the torque stations (110A-F) inhorizontally extended states (and station 110A in a partially broken outview).

FIG. 13 is a schematic side view one of the torque stations ready forthe beginning of a break out sequence as the driver socket is completelyretracted horizontally and moved to its highest vertical position whichwill clear the bolt being broken out along with being below the lowestpoint of the insulation or floatation for the upper riser section orjoint.

FIG. 14 is a schematic side view one of the torque stations moving to alocating position for the drive socket on the bolt head and showing howthe drive socket has been radially extended and also moved verticallydown before being located above the head of the bolt to be broken out.

FIG. 15 is a schematic side view of the torque station of FIG. 13illustrating the step of locating the drive socket on the bolt head forbreak out. Both low torque rotation along with high torque stroking isschematically shown for locating the drive socket on the bolt head priorto the high torque break out step.

FIG. 16 is a schematic side view of the torque station of FIG. 13 wherethe driver socket is engaged with the bolt, and the bolt has shoulder toshoulder contact with the upper flange, and the driver socket or socketis beginning the breakout process so that the torque station will gointo the high torque mode with the drive gear.

FIG. 17 is a schematic side view of the torque station of FIG. 13 wherethe driver tip or socket has partially broken out the bolt, spun out thebolt to where a free spinning mode has been entered because the threadsof the bolt are between the threads in the upper and lower flanges.

FIG. 18 is a schematic side view of the torque station of FIG. 13 wherethe lifting fork has engaged the freely spinning bolt and begun liftingthe bolt so that its threads can engage the threaded portion of theupper flange.

FIG. 19 is a schematic side view of the torque station of FIG. 13 wherethe lifting fork has lifted the bolt enough to now engage the threadedportion of the upper flange, and the lifting fork can later retract.

FIG. 20 is a schematic side view of the torque station of FIG. 13 wherethe lifting fork has retracted and the bolt has been additionally spunup compared to its position in FIG. 19, and is now located in the bolt'svertical position for retrieval of the section riser.

FIG. 21 is a schematic side view of the torque station of FIG. 13 wherethe driver socket has stopped rotating and has been vertically raisedabove the head of the bolt.

FIG. 22 is a schematic side view of the torque station of FIG. 13 wherethe driver socket is completely retracted both vertically andhorizontally and ready for the start of the next break out cycle.

FIG. 23 is a front perspective view of a torque station where the wrenchis set for tightening, and shown in a horizontally retracted positionwith the drive socket in the top most vertical position, and alsoshowing the lifting fork in a retracted position.

FIG. 24 is a front perspective view of the torque station of FIG. 23 nowshown in a horizontally extended position, and the lifting fork is alsoshown in an extended position.

FIG. 25 is a rear perspective view of the torque station of FIG. 23 nowshown in a horizontally extended position.

FIG. 26 is a side perspective view of the wrench and elevator portion ofthe torque station of FIG. 23 where the wrench is set for tightening,and the lifting fork is shown in an extended position.

FIG. 27 is a side perspective view of the wrench and elevator portion ofFIG. 26 but shown from the opposite side.

FIG. 28 is a top perspective view of the elevator portion shown in FIG.26.

FIG. 29 is a bottom perspective view of the elevator portion shown inFIG. 26 however with the lifting fork cylinders omitted for clarity.

FIG. 30 is an exploded perspective view of the high torque wrenchportion.

FIG. 31 is a top perspective view of a portion of the high torque driverof the wrench of FIG. 30.

FIG. 32 is an exploded perspective view of the high torque driver of thewrench of FIG. 30.

FIG. 33 is a enlarged top view illustrating the cylinder and pistonarrangement of the high torque driver of FIG. 30.

FIG. 34 is a top view of the high torque driver of the wrench of FIG. 30where the piston is in a completely retracted position.

FIG. 35 is a top view of the high torque driver of the wrench of FIG. 30where the piston is in the middle of a stroke.

FIG. 36 is a top view of the high torque driver of the wrench of FIG. 30where the piston is in a completely extended position.

FIG. 37 is a perspective view of a drive socket which can be operativelyconnected to the high speed low torque driver along with the high torquelow speed driver.

FIG. 38 is a top view of the socket of FIG. 37.

FIG. 39 is a bottom view of the socket of FIG. 37.

FIGS. 40 and 41 are respectively top and bottom views of the high torquedriver shown in FIG. 30.

FIG. 42 is a top perspective view of the sliding housing, reaction bar,and vertical lifting and lowering mechanism of FIG. 23.

FIG. 43 is a bottom perspective view of the sliding housing, reactionbar, and vertical lifting and lowering mechanism of FIG. 23.

FIG. 44 is a top perspective view of the base for the sliding housing ofFIG. 30.

FIG. 45 is a schematic diagram of the hydraulic circuits controlling thehigh torque driver, low torque driver, vertical lifting and loweringmechanism, sliding housing, and lifting fork during make up mode.

FIG. 46 is a schematic diagram of the hydraulic circuits controlling thehigh torque driver, low torque driver, vertical lifting and loweringmechanism, sliding housing, and lifting fork during break out mode.

FIG. 47 is a schematic diagram of the hydraulic circuits for thehydraulic power unit.

FIG. 48 is a schematic side view of the step of making up a riser stringof lowering a second riser section onto a first riser section where thefirst riser section along with the rest of the riser string is supportedby the spider.

FIG. 49 is a closeup side view of where the second riser section hasbeen placed on top of the first riser section showing a plurality ofriser bolts ready to be tightened with the spider supporting the riserstring and a plurality of torque modules are located in their homeposition.

FIG. 50 is a side view schematically indicating that the plurality oftorque modules shown in FIG. 49 have extended are making up theplurality of riser bolts while the riser string is being supported bythe spider.

FIG. 51 is a side view schematically indicating that the plurality oftorque modules have completed the make up of the plurality of riserbolts and such modules are retracting to their home position.

FIG. 52 shows the now made up joint between the second and first risersections is being lowered by the rig lifting elevator after the spiderhas been retracted.

FIG. 53 is a side view of the now made up joint between the second andfirst riser sections is being lowered by the rig lifting elevator (whichsupports the string by attachment to the upper flange of the secondriser section) after the spider has been retracted.

FIG. 54 is a side view of the elevator supporting the riser string bythe upper flange of the second riser section and located this upperflange in the spider for support.

FIG. 55 is a close up view of the elevator supporting the riser stringby the upper flange of the second riser section and having placed theupper flange on the spider for support.

FIG. 56 is a close up view of the elevator being removed from the upperflange of the second riser section.

FIG. 57 is a perspective view of all six torque modules in their homepositions and set up in the break out mode.

DETAILED DESCRIPTION

Detailed descriptions of one or more preferred embodiments are providedherein. It is to be understood, however, that the present invention maybe embodied in various forms. Therefore, specific details disclosedherein are not to be interpreted as limiting, but rather as a basis forthe claims and as a representative basis for teaching one skilled in theart to employ the present invention in any appropriate system, structureor manner.

U.S. Pat. Nos. 7,146,880; 6,553,873; and 6,382,059 are incorporatedherein by reference.

U.S. patent application Ser. No. 09/525,465, filed Mar. 13, 2000 isincorporated herein by reference.

Plurality of Wrenches

Hydraulic wrench apparatus 100 can comprise a plurality of torquestations each of which can include dual high and low torque wrenches(e.g., 110A, 110B, 110C, 110D, 110E, and 110F) for tightening (makingup) or loosening (breaking out) a plurality of bolts.

Each wrench (e.g., 110A, 110B, 110C, 110D, 110E, and 110F) can beconstructed in a substantially similar manner and, therefore, only onewrench 110 will be described below.

As indicated by vertical arrows 64 and 63 and horizontal arrows 60 and61, each wrench 110 (and driver 1000) can be robotically moved in bothvertical and horizontal directions allowing the wrenches to be cycled inand out during successive tightening or loosening activities of bolts indifferent sections of a riser 40.

Generally, each wrench 110 can include a wrench 400 which is adjustablymounted in a sliding housing 140. Wrench 400 can be adjusted verticallyrelative to sliding housing 140 as schematically indicated by arrows 64and 63. Additionally, sliding housing 140 can be adjustably mounted on abase 300. Sliding housing 140 can be adjusted horizontally relative tobase 300 as schematically indicated by arrows 60 and 61. In this mannerdriver tip or socket 1010 of wrench 400 can be both vertically andhorizontally adjustable when tightening or loosening a bolt 32.

In a preferred embodiment hydraulic wrench apparatus 100 will includesix (6) torque wrenches (e.g., 110A, 110B, 110C, 110D, 110E, and 110F)spaced radially apart in sixty degree increments around the bolt circleof two riser sections.

Structural Components

FIGS. 1 through 47 show one embodiment of wrench 100 having a pluralityof torque stations.

FIG. 1 is a top view of the rig floor 20 with the spider dogs in anextended state supporting the riser string 40 with the upper flange 47of a riser joint 46 exposed.

FIG. 2 is a perspective and sectional view of the spider 50 showing thespider dogs in an extended state.

FIGS. 3 and 4 are top views showing one embodiment of the torque wrenchsystem 100 in horizontally retracted and extended states in a make upmode. Preferably, all six stations (110A, 110B, 110C, 110D, 110E and110F) will simultaneously extend and retract.

FIGS. 5 through 10 show various sequence steps for one of the torquestations 110 during make up. Because all six torque stations (110A,110B, 110C, 110D, 110E and 110F) are substantially the same and operatesimilarly, only one representative torque station 110 will be describedin detail. However, it should be understood that the detail descriptionof the one applies equally to all six.

FIGS. 11 and 12 are top views showing one embodiment of the torquewrench system 100 in horizontally retracted and extended states in abreak out mode. Preferably, all six stations (110A, 110B, 110C, 110D,110E and 110F) will simultaneously extend and retract.

FIGS. 13 through 22 show various sequence steps for one of the torquestations 110 during break out. Because all six torque stations (110A,110B, 110C, 110D, 110E and 110F) are substantially the same and operatesimilarly, only one representative torque station 110 will be describedin detail. However, it should be understood that the detail descriptionof the one applies equally to all six.

FIGS. 23 through 44 are perspectives view of various components of oneof the torque stations 110 in multiple positions and performing multiplefunctions.

FIG. 23 is a front perspective view of a torque station 110 where thewrench 400 is set for tightening, and shown in a horizontally retractedposition (direction of arrow 61) with the driver tip 1010 in the topmost vertical position (schematically in the direction of arrow 64), andalso showing the lifting fork 1400 in a fully retracted position (in thedirection of arrow 61).

FIG. 24 is a front perspective view of torque station 110 now shown in ahorizontally extended position (direction of arrow 60), and the liftingfork 1400 is also shown in an extended position (direction of arrow 60).

FIG. 25 is a rear perspective view of torque station 110 now shown in ahorizontally extended position (direction of arrow 60).

FIG. 26 is a side perspective view of the wrench portion 400 of torquestation 110 where the wrench 400 is set for tightening, and the liftingfork is shown in an extended position (arrow 1402). FIG. 27 is a sideperspective view of the wrench portion 400 but shown from the oppositeside.

FIG. 28 is a top perspective view of the high speed/low torque driver1200 of wrench 400, and shown operatively connected to driver 1000 bymeans of belt 1220. Idler pulleys 1222 can maintain proper tension ofbelt 1220. FIG. 29 is a bottom perspective view of high speed/low torquedriver 1200 showing motor 1210 which is operatively connected to driver1000 through belt 1220. Although not shown one or more hydrauliccylinders and pistons can be operatively connected to fork 1400 toextend it (arrow 1402) or retract it (arrow 1404). Tracks 1252, 1254,1256, and 1258 of housing 1230 slidably connected to tracks 192, 194,196, and 198 of sliding housing 140 allowing housing 1230 to verticallyslide (arrows 64 and 63) relative to sliding housing 140 (see FIGS.23-25).

FIG. 30 is an exploded perspective view of a portion of the high torquedriver 590 of wrench 400. FIG. 31 is an assembled perspective view ofthe high torque driver 590. FIG. 32 is a perspective exploded view ofthe high torque driver 590.

FIG. 37 is a side perspective view of driver 1000 which can include tipor socket 1010, opening 1020 for bolt 32, and a maximum depth ofpenetration 1030 for the head of bolt 32. FIGS. 38 and 39 arerespectively top and bottom views of the driver 1000.

FIG. 40 is a perspective view of wrench body 406 used in torque station110. FIG. 41 is another perspective view of wrench body 406 taken fromthe opposite side as that shown in FIG. 40.

FIG. 42 is a front perspective view of the sliding housing 140, reactionbar 500, and vertical lifting and lowering mechanism 1300. FIG. 43 is abottom perspective view of sliding housing 140, reaction bar 500, andvertical lifting and lowering mechanism 1300. FIG. 44 is a topperspective view of base 300 for sliding housing 140.

The individual components and their operations will be described in moredetail below.

Wrench 110 can comprise a body 406 including a cylinder 700 forhydraulically reciprocating a piston 740 and piston rod 750. Piston 740being operably connected to a driver 1000. The connection between thepiston 740 and driver 1000 can be a ratcheting mechanism comprising adrive gear 600.

The high torque phase can be achieved by activation of hydrauliccylinder 700 pivotally connected to wrench body 406 by pivot pin 734.Piston rod 750 is connected to piston rod tip 760 which, in turn, isrespectively pivotally connected to first and second drive plates800,810 at bores 850, 852. First and second drive plates 800,810 arepivotally connected to drive pawl 900 through bores 860,870. Drive pawl900 is operatively connected to drive gear 600 by a plurality of angulargear teeth 610 and drive pawl springs 920. Drive plate extension 820biases springs 920 against drive pawl 900. Driver 1000 is connected todrive gear 600 through correspondingly shaped opening 620. Extension ofpiston rod 750 rotates first and second drive plates 800,810; therebyrotating drive pawl 900, thereby engaging drive gear 600 and turningdriver 1000 rotating driver tip or socket 110 and finally engaging bolt32.

Drive bushings/bearings 880 and 882 are operatively connected to driver1000 through bores 881 and 883. Drive bushings 880 and 882 fit intobores 460 and 470 of wrench body 406. Drive bushing/bearings 880 and 882reduce friction and act as a bearing surface during rotation of driver1000 for both high speed and high torque phases.

Wrench 400 can include a reaction bar 500 which provides a reactingforce in opposition to the torque applied by driver 1000 on bolt 32.Driver 1000 can be operably connected to a driver tip or socket 1010which itself connects to threaded fastener 32. In one embodiment therecan be further included exchangeable socket tips mountable on driver1000 for engaging a head of a threaded fastener 32 which are ofdifferent sizes.

Sliding housing 140 can slide radially, laterally, or horizontallyrelative to base 300 (in the directions of arrows 60 and 61). Slidinghousing 140 can comprise top 142, bottom 144, front 146, and rear 146.Sliding housing can include first and second side walls 152, 154, whichare connected by horizontal braces 180 and 170. On the bottom 144 can beplurality of foot connectors 154, 155, 156, and 157, each of which caninclude a sliding bore.

Sliding housing 140 can include reaction bar or shaft 500 which spansbetween brace 170 and removable brace 160.

Side wall 150 can include tracks 192 and 194. Substantially opposite oftracks 192 and 194 can be tracks 196 and 198 located on side wall 152.Male tracks 192, 194, 196, and 198 can slidably connect wrench 400located on top of housing 1230 (in a vertical direction and cooperatingwith female tracks 1252,1254, 1256, and 1258) to sliding housing 140.Wrench 400 will also slide vertically relative to reaction bar or shaft500 through cooperating bore 498.

Sliding housing 140 can be adjustably mounted on a base 300 through footconnectors 154, 155 and 156, 157 being slidably connected to shafts 352and 354. Sliding housing 140 can be adjusted horizontally relative tobase 300 as schematically indicated by arrows 60 and 61. A pair ofhydraulic cylinders and pistons (not shown) can be connected to slidinghousing 140 and rear plate 358 such that extension of the cylinderspushes sliding housing 140 in the direction of arrow 60 (at least untilthe fully extended position where front plate 356 can stop furthermovement in the direction of arrow 60) and retraction of the cylinderspulls sliding housing 140 in the direction of arrow 61. In oneembodiment a maximum forward movement adjustment mechanism (such as aset screw) can be provided on front plate 356 to limit the amount ofhorizontal movement of sliding assembly (and driving tip or socket 1010)in the direction of arrow 60. For example, forward movement in thedirection of arrow 60 can be stopped when foot 156 and/or 157 hitsforward plate 356. In one embodiment the distance of forward movement inthe direction of arrow 60 can be controlled by measuring the amount ofextension of the hydraulic cylinders pushing sliding housing 140.

Vertical lifting and lowering mechanism 1300 can comprise motor 1310 andscrew 1330. Hydraulic motor 1310 can be operatively connected to screw1330. Screw 1330 can be operatively connected to wrench 400 throughthreaded area 1242 of housing 1230. Rotating in the direction of arrow1332 (clockwise) would lower wrench 400 (in the direction of arrow 63),while rotating in the opposite direction (i.e., in the direction ofarrow 1334 or counterclockwise) would raise wrench 400 (in the directionof arrow 64). Although not shown in the drawings, in one embodimentvertical lifting and lowering mechanism can comprise a cylinder andpiston arrangement operatively connected to wrench 400 where extensionof the cylinder raises wrench 400 (in the direction of arrow 64) andretraction of the cylinder lowers wrench 400 (in the direction of arrow63). However, given the small clearance between wrench 400 and base 300when wrench 400 is in its lowest position a telescoping arrangement maybe required or the piston connection being made at the rear of wrenchbody 406. The vertical positioning mechanism can vertically position thedrive head independent from the operation of the high torque and lowtorque wrenches.

In one embodiment a bolt lifting mechanism 1400 is provided. Boltlifting mechanism 1400 can comprise lifting fork 1410 and plate 1420.Lifting fork 1410 can be slidingly connected to wrench 400 via housing1230 by plate 1420 sliding in between tracks 1430 and 1432. A pair ofhydraulic cylinders and pistons (not shown) can be connected to plate1420 and extension of the cylinders pushes fork 1410 in the direction ofarrow 1402 (at least until the fully extended position where fork 1410is blocked from further movement in this direction such as by contactingbolt 32) and retraction of the cylinders pulls fork 1410 in thedirection of arrow 1404. In one embodiment a maximum forward movementadjustment mechanism (such as a set screw) can be provided to limit theamount of horizontal movement of fork 1410 in the direction of arrow1402. In one embodiment the distance of forward movement in thedirection of arrow 1402 can be controlled by measuring the amount ofextension of the hydraulic cylinders pushing fork 1410.

High and Low Torque Portions

Each wrench 110 can have both high torque and low torque drivingmechanisms. Each wrench 110 can have a high speed/low torque portion1200 for speeding up the tightening or loosening process until a highertorque is required/desired. When a higher torque is desired each wrench110 can include a low speed/high torque portion 590 which can addressfinal make-up torquing up of bolts 32 or the initial break out torquefor breaking out bolts 32.

In one embodiment the high and low torque portions of each wrench 110can be switched during a cycle of tightening or loosening a bolt 32. Inone embodiment the switch from high to low or low to high torque optionscan be based on height. In one embodiment the height can be measuredusing a height sensor 1350 for elevator 1200 which height sensor can becommercially available. In one embodiment the height sensor 1350 can bea linear variable detection transducer.

In one embodiment the high and low torque portions of each wrench 110can be switched as many times as needed when tightening or loosening abolt 32. The operations of each will be described below.

In one embodiment the high and low torque portions of each wrench 110can be simultaneously energized. During requirements of low torque, thehigh speed portion 1200 takes over because it spins driver tip or socket1010 faster than the low speed/high torque 590 portion. In this casedrive gear 600 merely spins faster than low speed/high torque 590portion attempts to turn drive gear 600 (by pawl 900 performing aratcheting motion against biasing members 920 as drive gear 600 turnsfaster than piston 740 and pawl 900 attempt top turn drive gear 600).During requirements of high torque, the motor 1210 from the high speedportion 1200 “stalls” and the high torque 590 takes over (albeit at aslower rotational speed). In this manner each wrench 110 can transitionbetween high and low torque modes as frequently and as many times asneeded during either tightening (making up) or loosening (breaking out)a bolt 32.

Torque wrench 110 can comprise a driver 1000 with tip or socket 1010configured to engage a threaded connector 32 such as a bolt or nut.Socket head 1010 also comprises a plurality of faces or socket teethradially positioned. Hydraulic wrench assembly 110 further comprises ahydraulic cylinder 700. Hydraulic cylinder 700 is configured to extendand retract a drive pawl 900 which is positioned to engage ratchet teeth610 upon extension of pawl 900. When pawl 900 engages ratchet teeth 610,driver 1000, driver tip or socket 1010, and threaded connector 32 arerotated upon further extension of pawl 900, which will either tighten orloosen threaded connector 32 depending upon the direction of rotation ofdriver 1000. Pawl 900 may retracted and extended again, further rotatingdriver 1000 and driver tip or socket 1010, and threaded connector 32until the desired torque is reached or until threaded connector 32 isadequately loosened.

Torque wrench 110 further comprises a high speed/low torque driver 1200which can include a hydraulic motor 1210 which is mechanically coupledto driver 1000 (such as through a belt, toothed belt, or chainconnection) so that operation of high speed driver 1200 will result indriver 1000 along with driver tip or socket 1010, and threaded connector32 being rotated at a relatively high rotational speed. Typically, highspeed/low torque driver 1200 will rotate at about 100 rpm and will beconfigured to provide about 500 ft lbs of torque to threaded connector32. Driver 1200 can be used until threaded connector is snug, acondition that will be apparent when motor 1210 stalls, and driver 1000stops turning.

In one embodiment high Speed/low torque driver 1200 will stop turningwhen the reaction force or torque from tightened bolt 32 equals thetorque placed by driver 1200 (e.g., piston 740, piston rod 750, driveplates 800,810, and pawl 900 on drive gear 600). This state can becalled “stalled” or “being torqued out.” Hydraulic motor 1210 stalls outand acts as blockage in the hydraulic line feeding it. As the pressurebuilds up, the pressurized fluid causes hydraulic motor 1210 to rotatewhich allows the fluid to pass and prevents the pressure from buildingup further. However, if resistance from threaded connector 32 preventsmotor 1210 from rotating, the pressure will continue to increase untileither that obstacle is overcome and motor 1210 rotates allowing some ofthe fluid to pass or until relief is obtained elsewhere (such as by thehigh torque portion 590 taking over). As bolt 32 gets tighter, it willprovide more and more resistance to rotation of motor 1210. As threadedconnector 32 gets tighter and tighter, the pressure in the hydraulicline will be increased ever higher.

In one embodiment both the high speed/low torque 1200 and low speed/hightorque driver 590 portions are continuously hydraulically energized.During “low torque” phases of turning bolt 32 the high speed motor 1210will “stall” and the high torque driver 590 will continue to turn bolt32 either until bolt 32 is made up to an acceptable torque or the torqueon bolt 32 drops and the high speed motor 1210 will again take over. Inone embodiment when the back pressure from motor 1210 reaches a stalledcondition operation is switched to low speed/high torque wrench 410.

Reaction Torque

During both high speed and high torque phases reaction bar 500 willprovide the reaction force to counteract the reaction torque generatedby either tightening or loosening bolt 32. During operation a reactiontorque (or force) equivalent to the torque applied by torque wrench 110will be generated when removing or tightening bolt 32. This reactiontorque must be compensated for, such as by having reaction bar 500transmit such torque to the structure of the rig 20 and/or riser 40.

In one embodiment the reaction torque from bolt 32 is transferred todriver 1000 and wrench body 406 to reaction bar 500, and from reactionbar 500 to braces 160 and 170, to feet 155 and 157, to shafts 352 and354, and to base 300. In one embodiment base 300 is connected to spider50 which itself can be connected to the floor of rig 10 (even if byfriction) and such reaction torque is transferred to the floor of rig10.

In one embodiment bases 300A-F are interconnected (but sitting on thefloor of rig 10 without being bolted down), and the reaction torque isultimately transferred from each of the bolts 32A-F to one or more ofthe other bolts 32A-F, and to the upper and/or lower riser sections 42and 46 through the flanges 43 and 47.

Control Units

In one embodiment a single control unit 80 is used for torque modules110A-F. In one embodiment a control unit is used to control multiplewrenches (e.g., 2, 3, 4, 5 and/or 6). In one embodiment each wrench(e.g., 110A-F) has its own control unit.

General Sequence Steps

FIGS. 3 through 10 show various sequence steps in a make up process forone of the torque stations.

FIGS. 11 through 22 show various sequence steps in a break out processfor one of the torque stations.

Each process will be described below for one embodiment.

Make-Up Sequence

FIGS. 3 through 10 show various sequence steps in a make up process forone of the torque stations. Only one of the torque stations 110 is shownas all six follow substantially the same process—although each station110 can act independently of the other stations for the described stepsunless specified otherwise.

FIG. 3 is a top view showing one embodiment of the torque wrench systemduring make up with all six of the torque stations (110A-F) inhorizontally retracted states (and station 110A in a partially brokenout view).

FIG. 4 is a top view showing one embodiment of the torque wrench systemduring make up with all six of the torque stations (110A-F) inhorizontally extended states (and station 110A in a partially broken outview).

FIG. 5A is a schematic side view one of the torque stations 110 readyfor the beginning of a make up or break out sequence as the driversocket is completely retracted horizontally (arrow 61) and moved to itshighest vertical position (arrow 64) which will clear a bolt 32previously placed in a storage condition for a riser joint 42 along withbeing below the lowest point of the insulation or floatation(schematically indicated by numerals 44) for the upper riser section orjoint 42. FIG. 5B is a top view of the torque station of FIG. 5A shownin partially broken out view.

FIG. 6A is a schematic side view of torque station 110 where drivesocket 1010 has moved horizontally (arrow 60) over a bolt 32 and isrotating for tightening (arrow 66), the drive socket or tip 1010 is alsomoving downwardly (arrow 63), and is about to engage the head of bolt32. FIG. 6B is a top view of the torque station 110 shown in partiallybroken out view.

FIG. 7A is a schematic side view of torque station 110 where drivesocket or tip 1010 has engaged the bolt 32 and begun to spin down thebolt 32 through the upper flange 47 and into the gap 49. FIG. 7B is atop view of the torque station 110 shown in partially broken out view.

FIG. 8A is a schematic side view of the torque station 1105 after thedrive socket 1010 has spun down the bolt 32, and the bolt 32 is nowallowed a free fall through the gap between the flanges 43 and 47, andthe head of the bolt 32 has vertically dropped in relation to the drivesocket 1010. Free fall occurs and bolt 32 drops a distance such as 1inch but its head remains in socket 1020 of tip 1010 because of excesscapacity depth 1030. FIG. 8B is a top view of the torque station 110shown in partially broken out view.

FIG. 9A is a schematic side view of the torque station 1105 after thedrive socket 1010 has spun down the bolt 32, allowed a free fall of thebolt 32 through the gap 49 between the flanges 43 and 47, and furtherspun down the bolt 32 to the lower flange 47 by about two threads in thelower flange 47. FIG. 9B is a top view of the torque station 110 shownin partially broken out view.

FIG. 10A is a schematic side view of the torque station 110 after thedrive socket 1010 has spun down the bolt 32 until shoulder to shouldercontact between the upper flange 43 and the bolt head has occurred, andthe torque station 110 goes into a high torque mode where the piston 740and cylinder 700 control rotation of the driver 1000. After the desiredmake up torque is achieved the driver tip 1010 will be moved upward andretracted (arrows 64 and 61) to the position shown in FIG. 5 and beready for the next make up cycle.

Now the general method for one embodiment will be described for the makeup mode.

In the beginning all six modules (110A-F) are in the fully retractedposition (which can be called the home position). Previous to module 110extension, there can be a safety check to make sure that all six modules(110A-F) are in the home position before a make-up routine can bestarted. The home position can be both a vertical home position (arrow64—which can be checked by the vertical height sensor 1350) along with ahorizontal radially retracted home position (arrow 60—which can bechecked by a timing sequence using the body slide cylinders 362 and 364,such as retraction hydraulic pressure for a set period of time which canbe 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 seconds of retraction pressure).Fully retracted positions can be controlled by fully retracted bodyslide cylinders 362 and 364, or by a retraction catch (e.g., rear plate358), or a combination of the two. In one embodiment there can be anadjustable body retraction stop (e.g., rear plate 358) for each bodymodule (110A-F) in the retraction step.

Pressing the start button (e.g., located on control panel 80) for makeup causes all six modules (110A-F) to be radially extended in thedirections of arrow 61 (by the body slide cylinders 362 and 364extending) and causing the modules (110A-F) to radially extend (arrows61A-F) such that the individual drive sockets (1010A-F) will bepositioned over the individual bolts (32A-F). Radial extension ofmodules (110A-F) occurs on both a timing control along with a radialextension stop (e.g., extension adjusters 357 on front plate 356). Inone embodiment there can be an adjustable body extension stop 357 foreach body module 140 in the extension step. In one embodiment radialextension (in the direction of arrow 61) can be checked by a timingsequence using the body slide cylinders (362 and 364), such as extensionhydraulic pressure for a set period of time which can be 1, 2, 3, 4, 5,6, 7, 8, 9, and 10 seconds of extension pressure.

In one embodiment, after a set period of time following the release ofhydraulic pressure to each of the body slide cylinders (362 and 364),each of the drive socket 1010 is lowered (in the direction of arrow 63).In one embodiment the set period of time can be ½, ¾, 1, 1½, 2, 3, 4,and 5 seconds. In various embodiments the set period of time can bewithin a range of between any two of the above set periods of time.

In one embodiment, at the beginning of the lowering step (FIG. 6A), eachdrive socket 1010 can be rotated (in the direction of arrow 66) usingthe high speed/low torque driver 1200 at a first rotational speed (whichis lower than a second rotational speed). In various embodiments therelative rotational speeds can be 5, 10, 15, 20, 25, 30, 35, 40, 45, 50,55, 60, 65, 70, 75, 80, 85, 90, 95, and 100 percent of each other. Invarious embodiments the relative rotational speeds can be within a rangeof between any two of the above specified percentages.

In one embodiment the first rotational speed (in the direction of arrow66) of each individual drive socket (1010A-F) is continued until a setheight (H2 shown in FIG. 9A) of the individual drive socket head isreached. In one embodiment the switch from first to second verticalspeeds (in the direction of arrow 63) corresponds with the bolt 32dropping between the threaded sections of the two riser flanges (gap 49)and entering the threaded section of the lower riser flange 47. In oneembodiment this set height of the drive socket 1010 is based on theriser bolt 32 being threadably engaged with the threads of the lowerriser flange joint 47. In one embodiment this height is based on anengagement of at least 2 threads. In one embodiment each of the sixmodules 110 are individually controlled based on the height H of theindividual drive sockets 1010.

In one embodiment the rate of vertical movement (in the direction ofarrow 63) of each drive socket (1010A-F) has a first vertical speed anda second vertical speed during vertical drop (in the direction of arrow63) of each drive socket (1010A-F). In one embodiment the first verticalspeed can be lower than a second vertical speed). In various embodimentsthe relative vertical speeds can be 5, 10, 15, 20, 25, 30, 35, 40, 45,50, 55, 60, 65, 70, 75, 80, 85, 90, 95, and 100 percent of each other.In various embodiments the relative vertical speeds can be within arange of between any two of the above specified percentages. In oneembodiment the switch from the first vertical speed to the secondvertical speed can be simultaneous with the switch from the firstrotational speed to the second rotational speed.

In one embodiment each of the drive sockets (1010A-F) are checked todetermine that a lower specified vertical height (H3 shown in FIG. 10A)has been achieved before a high torque mode is entered with each of thedrive sockets (1010A-F). In one embodiment a set period of time iswaited from the last drive socket reaching its specified ending verticalheight (H3) before high toque mode is entered. In one embodiment the setperiod of time can be ½, ¾, 1, 1½, 2, 3, 4, and 5 seconds. In variousembodiments the set period of time can be within a range of between anytwo of the above set periods of time.

In one embodiment each of the drive sockets (1010A-F) respectively spindown its riser bolt (32A-F) until a snug condition is achieved betweenthe riser bolt and the joint before a high torque mode is simultaneouslyentered with each of the drive sockets (1010A-F). In one embodiment asnug connection between the riser bolt and the joint is less than about600, 500, 400, 300, 200, 100, 50, 25, and 0 foot pounds of torquebetween the riser bolt and the joint connection. In various embodimentseach of the riser bolts is within the same range of between about anytwo of the above specified torques. In one embodiment a set period oftime is waited from the last bolt reaching its snuggling torque beforehigh toque mode is entered. In one embodiment the set period of time canbe ½, ¾, 1, 1½, 2, 3, 4, and 5 seconds. In various embodiments the setperiod of time can be within a range of between any two of the above setperiods of time.

In one embodiment each of the drive sockets (1010A-F) are started in thehigh torque mode simultaneously. In one embodiment each of the drivesockets (1010A-F) are continued in the high torque mode until a pre-setback pressure is achieved (and the high torque mode hydraulicallystalls). In one embodiment the set period of time can be 1, 2, 3, 4, 5,6, 7, 8, 9, and 10 seconds of extension pressure. In various embodimentsthe set period of time can be within a range of between any two of theabove set periods of time.

In one embodiment the final make-up torque between each of the riserbolts (32A-F) for a particular riser joint are within less than about10, 9, 8, 7, 6, 5, 4, 3, 2, 1, ½ percent of each other's make-uptorques. In various embodiments the final make-up torques can be withina range of between about any two of the above specified percentages.

In one embodiment a set period of time is specified for each of thedrive cylinders (700A-F) of the drive sockets (1010A-F) to reach thepreset torquing pressure, and if not met a warning signal is sent out.In one embodiment along with the warning sign the system is shut downfor diagnostic checking.

In one embodiment where each of the drive sockets (1010A-F) reach andmaintain the pre-set back pressure each of the drive sockets (1010A-F)are then sent back to the home position (retracted vertically in thedirection of arrow 64 and horizontally in the direction of arrow 60). Inone embodiment the retracted vertical mode is achieved before the startof retraction in a horizontal mode. In one embodiment the drive socket1010 is not spun either in high speed or in high torque duringretraction. In one embodiment retraction vertically is checked by avertical height sensor 1350. In one embodiment retraction horizontally(in the direction of arrow 60) is by a pre-set time period. Thehorizontal radially retracted home position can be checked by a timingsequence using the body slide cylinders 362 and 364, such as retractionhydraulic pressure for a set period of time which can be 1, 2, 3, 4, 5,6, 7, 8, 9, and 10 seconds of retraction pressure. In variousembodiments the set period of time can be within a range of between anytwo of the above set periods of time. Fully retracted positions can becontrolled by fully retracted body slide cylinders 362 and 364, or by aretraction catch (rear plate 358), or a combination of the two. In oneembodiment there can be an adjustable body retraction stop (e.g.,adjustable fasteners in rear plate 358) for each body module (110A-F) inthe retraction step.

In one embodiment the made up riser flange (43 and 47) is lowered, and anew section of riser 42′ is placed on the riser (on top of riser section42) for make-up. In one embodiment the above specified steps arerepeated for attaching the new section of riser (42′ being attached to42).

In one embodiment the above specified steps are repeated until thelength of riser 40 spans from the sea floor (well head or blow outpreventer) to the rig or platform.

Break-Out Sequence

To place torque module 110 in the breakout mode (i.e., to loosen bolt32) compared to the make up mode, wrench 400 will have to be flippedover so that bottom 420 is now above top 410. This can be accomplishedrelatively easily by removal of brace 160, and sliding upward in thedirection of arrow 64 wrench 400. Bores 460, 470 will allow wrench 400to slide over driver shaft of driver 1000. Bore 490 will allow wrench400 slide over screw 1330. Bore 498 will allow wrench 400 to slide overreaction shaft or bar 500. High speed/low torque driver 1200 canmaintain its position. Once flipped over (i.e., bottom 420 being abovetop 410), wrench 400 can again be placed on high speed/low torque driver1200 with bores 460,470 again going over shaft of driver 1000, bore 490over screw 1330, and bore 498 over reaction shaft or bar 500. Brace 160is again placed over reaction bar or shaft 500.

FIGS. 11 through 22 show various sequence steps in a break out processfor one of the torque stations 110. Only one of the torque stations 110is shown as all six follow substantially the same process—although eachstation 110 can act independently of the other stations for thedescribed steps unless specified otherwise.

FIG. 11 is a top view showing one embodiment of the torque wrench systemduring break out with all six of the torque stations (110A-F) inhorizontally retracted states (and station 110A in a partially brokenout view showing various individual components). FIG. 12 is a top viewshowing one embodiment of the torque wrench system during break out withall six of the torque stations (110A-F) in horizontally extended states(and station 110A in a partially broken out view).

FIG. 13 is a schematic side view one of the torque stations 110 readyfor the beginning of a break out sequence as the driver socket 110 iscompletely retracted horizontally and moved to its highest verticalposition (arrow 64) which will clear the particular bolt 32 being brokenout along with being below the lowest point of the insulation orfloatation for the upper riser section or joint (schematically shown bylines 44). This position can be called the home position.

FIG. 14 is a schematic side view one of the torque stations 110 moving(schematically indicated by arrows 63 and 60) to a locating position forthe drive socket 1010 on the bolt 32 head and showing drive socket 1010after being partially radially extended (in the direction of arrow 60)to now move within a projected cylinder of the insulation 44(schematically shown by dashed line 44′), and also moved vertically down(in the direction of arrow 63) to height H1 before being positionedabove the head of its respective bolt 32 to be broken out. At height H1,drive socket 1010 can begin to be rotated at a first speed in thedirection of arrow 68. In one embodiment height H1 will be about ½ inchabove the top of the head of bolt 32. Also at H1, the downward speed ofdrive socket 1010 can be reduced (such as to 1, 2, 3, 4, 5, 6, 7, 8, 9and/or 10 inches per minute) during the time it is being located on bolt32.

FIG. 15 is a schematic side view of the torque station 110 illustratingthe step of locating (and engaging) the drive socket 1010 on the bolt 32head for break out. As will be described below both low torque rotationusing motor 1210 (schematically indicated by arrow 68) along withlocating high torque stroking (schematically indicated by arrows 772 an774) can be used during the locating step for drive socket 1010 beforebeginning the high torque break out step. As will be described belowlocation of drive socket 1010 on bolt 32 can be determined when drivesocket 1010 drops (in the direction of arrow 63) from height H2 (FIG.15) to height H3 (FIG. 16).

FIG. 16 is a schematic side view one of the torque stations 110 wherethe drive socket 1010 is located on bolt 32, bolt 32 has shoulder toshoulder contact with the upper flange 43, and the drive tip or socket1010 is beginning the breakout process in high torque mode (arrows 772and 774) so that the torque station 110 will go into the high torquemode with the drive gear 600.

FIG. 17 is a schematic side view of torque station 110 where the drivetip or socket 1010 has partially broken out the bolt 32, spun out thebolt (arrow 68) to where a free spinning mode has been entered becausethe threads of the bolt 32 are in gap 49—between the threads in theupper 43 and lower 47 flanges. In this figure arrow 68 schematicallyindicates the spinning out of bolt 32.

FIG. 18 is a schematic side view of torque station 110 where liftingfork 1400 has engaged the freely spinning bolt 32 (arrow 1402) and begunlifting (arrow 64) the bolt 32 so that its threads can engage thethreaded portion of upper flange 43. In this figure arrow 68schematically indicates the free spinning of bolt 32.

FIG. 19 is a schematic side view of torque station 110 where liftingfork 1400 has lifted (arrow 64) the bolt 32 enough to now engage thethreaded portion of the upper flange 43, and the lifting fork can laterretract. In this figure arrow 68 schematically indicates the spinningout of bolt 32.

FIG. 20 is a schematic side view of torque station 110 where liftingfork 1400 has retracted (arrow 1404) and the bolt 32 has beenadditionally spun up (arrow 64) compared to its position in FIG. 19, andis now located in the bolt's vertical position for retrieval of thesection riser 42 (H_(s) or Hstorage). In this figure arrow 68schematically indicates the final spinning out of bolt 32 to its storageposition in flange 43.

FIG. 21 is a schematic side view of the torque station 110 where thedrive socket 1010 has stopped rotating and has been vertically (arrow64) raised above the head of the bolt 32 (H_(cl) or Hclearance). At thispoint the threaded portion of bolt 32 can be protected by flange 32during storage. Also at this point there still is clearance under thefloatation or insulation of the riser joint or section 42.

FIG. 22 is a schematic side view of torque station 110 where the drivetip or socket 1010 is completely retracted horizontally (arrow 61) andready for the start of the next break out cycle.

In one embodiment (FIGS. 9 and 16) the height H to the driving tip orsocket 1010 is positioned above the maximum height of the tightened headof bolt 32 to be loosened. Vertical positioning of driving tip or socket1010 can be accomplished by using vertical lifting and loweringmechanism 1300. Horizontal positioning of driving tip or socket 1010 canbe accomplished using adjustable sliding housing 140. In one embodimentboth vertical and horizontal movement is accomplished simultaneously toreduce the amount of time before loosening can be started (and reducethe overall cycling time).

Risers 40 are made up of a plurality of riser sections 42, 46, etc) andtypically come in standard sizes and specifications so that bolts 32 ina tightened condition will be at a known maximum height. Additionally,the maximum height of bolt 32 when loosened can be calculated.Accordingly, the minimum height H (FIG. 16) for driving tip or socket1010 can be calculated relatively easily before loosening can begin.Additionally, the maximum height of the top of wrench 400 at the end ofthe loosening cycle should be below the bottom of the insulation orfloatation 44 found on the riser 40 section being broken (otherwise thewrench 400 or torque station 110 could damage the insulation orfloatation 44). The distance between the insulation or floatation 44 andthe riser flange (e.g., flange 43 of upper riser section 42 shown inFIG. 9) typically is made to a specified distance and the maximum heightcan be easily determined. Although not shown in the drawings, in oneembodiment a physical vertical limit is placed on the maximum height ofhigh torque driver 590 to make sure that driver (or body 406 of wrench400) does not rise above a specified level. In one embodiment thisphysical limit is a limiting brace on sliding housing 140.

Now the general method will be described for one embodiment in break outmode.

In the beginning all six modules (110A-F) are in the fully retractedposition (horizontally in the direction of arrow 61 and vertically inthe direction of arrow 64—which can be called the home position).Previous to body 140 extension, there can be a safety check to make surethat all six modules (110A-F) are in the home position before a make-uproutine can be started. The home position can be both a module verticalhome position (in the direction of arrow 64—which can be checked by thevertical height sensor 1350) along with a horizontal radially retractedhome position (in the direction of arrow 60—which can be checked by atiming sequence using the body slide cylinders 362 and 364, such asretraction hydraulic pressure for a set period of time which can be 1,2, 3, 4, 5, 6, 7, 8, 9, and 10 seconds of retraction pressure). Fullyretracted positions can be controlled by fully retracted body slidecylinders 362 and 364, or by a retraction catch (e.g., rear plate 358),or a combination of the two. In one embodiment there can be anadjustable body retraction stop (e.g., limiter 359) for each body module(110A-F) in the retraction step.

Pressing the start button (e.g., located on control panel 80) forbreak-out causes all six modules (110A-F) to be radially extended (inthe direction of arrow 60 by the body slide cylinders 362 and 364extending) and causing the modules (110A-F) to radially extend (arrows60A-F) such that the individual drive sockets (1010A-F) will bepositioned over the individual bolts (32A-F). Radial extension ofmodules (110A-F) occurs on both a timing along with a radial extensionstop (e.g., extension adjusters 357 on front plate 356). In oneembodiment there can be an adjustable body extension stop (357A-F) foreach body module (140A-F) in the extension step. In one embodimentradial extension (in the directions of arrows 60A-F) can be checked by atiming sequence using the body slide cylinders (362A-F and 364A-F), suchas extension hydraulic pressure for a set period of time which can be 1,2, 3, 4, 5, 6, 7, 8, 9, and 10 seconds of extension pressure.

In one embodiment, during horizontal extension (in the directions ofarrows 60A-F) of each of the body slide cylinders (362A-F and 364A-F),each of the drive sockets (1010A-F) can be lowered (in the direction ofarrow 63). In one embodiment rotation of the drive sockets (1010A-F) ata first rotational speed (in the direction of arrow 68) begins when theindividual drive socket (1010A-F) reaches a first vertical height (H1).In one embodiment, the first rotational speed can be lower than a secondrotational speed during actual spin out of bolts (32A-F). In variousembodiments the relative rotational speeds can be 5, 10, 15, 20, 25, 30,35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, and 100 percent ofeach other. In various embodiments the relative rotational speeds can bewithin a range of between any two of the above specified percentages. Inone embodiment at the time of beginning rotation of the drive socket(1010A-F) the horizontal body slide cylinders (362A-F and 364A-F) arehydraulically relaxed.

In one embodiment each drive socket 1010 is rotated at the firstrotational speed (in the direction of arrow 68) until the drive socket1010 reaches a second vertical height (H2 as shown in FIG. 15) at whichtime the high speed low torque motor 1200 is stopped and hydraulicallyrelaxed. In one embodiment the second vertical height H2 is such thatdrive socket 1010 is about 1½, 1, or ½ inches over the bolt 32 head. Atthis same time vertical movement (in the direction of arrow 63) of thedrive socket 1010 is stopped and the hydraulic motor 1310 driving thevertical positioning screw 1330 is hydraulically relaxed for a setperiod of time. In one embodiment the set period of time can be ½, ¾, 1,1½, 2, 3, 4, and 5 seconds. In various embodiments the set period oftime can be within a range of between any two of the above set periodsof time.

In one embodiment, after the set period of time, the verticalpositioning screw 1300 attempts to move the drive socket 1010 to a thirdvertical height H3 and holds the drive socket 1010 at this height H3. Inone embodiment H3 is about 1½, 1, or ½ inches in the direction of arrow63 compared to H2.

In one embodiment if the third vertical height H3 of drive socket 1010is not achieved within a set period of time at a particular torquingstation, at least one locating high torque stroke (schematicallyindicated by arrows 772 and 774 in FIG. 15) is made on the drive socket1010 to assist in locating the drive socket 1010 on the bolt 32 head anda further check on the vertical height of the drive socket 1010 is madeto determine engagement of the bolt 32 head by the drive socket 1010. Inone embodiment the vertical positioning screw 1300 continues to attemptto pull down (in the direction of arrow 63) the drive socket 1010 whilethe locating high torque stroke is made. In one embodiment the setperiod of time can be ½, ¾, 1, 1½, 2, 3, 4, and 5 seconds. In variousembodiments the set period of time can be within a range of between anytwo of the above set periods of time.

In one embodiment after the first iteration of the locating drive strokeis made and the locating high torque stroke is not achieved for thedrive socket 1010, a second iteration of locating drive stoke is madeand the vertical height (H) of the drive socket 1010 is checked todetermine if the drive socket has dropped to height H3 (and beenproperly located on the bolt 32 head). In various embodiment multipleiterations of locating high torque strokes can be made along with checksof the vertical heights of the drive socket 1010, until engagement ofthe bolt 32 head is determined. In one embodiment the verticalpositioning screw 1300 continues to attempt to pull down the drivesocket 1010 while the locating high torque stroke is made. In variousembodiments, before each locating high torque stroke is made, verticalmovement of the drive socket 1010 is stopped. In one embodiment thevertical control system is also relaxed before each locating high torquestroke is made. In various embodiments, before each locating high torquestroke is made, rotation of the drive socket 1010 is stopped. In oneembodiment the high speed rotational motor 1310 is also relaxed beforeeach locating high torque stroke is made. In various embodiments, beforeeach locating high torque stroke is made, the radial positioning system(362 and 364) for the drive socket 1010 is also relaxed. In oneembodiment, a warning signal is sent if one or more torquing stationsare not able to be located on their respective bolt head within a setperiod of time (i.e., step “d”), or within a set number of high torquelocating strokes.

In one embodiment at the time the vertical positioning screw 1300 isstopped, the drive socket 1010 enters a high torque break-out mode(using high torque driver 590) and schematically indicated in FIG. 16.In one embodiment the high torque mode is cycled (strokes of wrench 400)for a set number of stroking cycles. In one embodiment the set number ofcycles can be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17,18, 19, 20, 21, 22, 23, 24, 25, 30, 35, 40, 45, and 50. In variousembodiments the set number of cycles can be within a range of betweenany two of the above set number of cycles. In one embodiment after itslast cycle, the high torque system (piston 740 and rod 750) fullyretracts. In one embodiment full retraction is determined by a timingsequence using the high torque hydraulic cylinder, such as extensionhydraulic pressure for a set period of time which can be ½, ¾, 1, 1½, 2,3, 4, and 5 seconds. In various embodiments the set period of time canbe within a range of between any two of the above set periods of time.

In one embodiment each of the drive sockets (1010A-F) are started in thehigh torque mode simultaneously. In this embodiment proper location ofeach of the six drive sockets is made (FIGS. 15 to 16) before the hightorque break out mode for any one of the drive sockets is started.

In one embodiment the high torque mode is switched to low torque modeafter a specified lower back pressure is achieved on the high torquesystem 590. In one embodiment a check can be made on the low torque highspeed system 1200 to see if it stalls when breaking out the bolt 32. Inone embodiment the stalling condition is determined based on reaching aspecified back pressure for the motor 1210. In one embodiment thestalling condition is determined upon falling below a specified flowrate through the motor 1210.

In one embodiment during the high torque breakout mode the drive socket1010 is not moved vertically upward (in the direction of arrow 64) byvertical screw 1330. Instead, in this embodiment vertical movement (inthe direction of arrow 64) of the drive socket 1010 is taken up by avertical angular turning (in the direction of arrow 70) of the torquewrench body 590. In one embodiment this differential vertical angularturning of the torque wrench body 590 is relieved when the bolt 32leaves the threads of the lower flange 47, and is located in the gap 49between the upper 43 and lower 47 flanges, and is being raised by thelifting fork 1410. In one embodiment the arms of the lifting fork 1410are located a set distance below the tip of the drive socket (1010A-F).In one embodiment the set distance is about ¼, ⅜, ½, ⅝, ¾, ⅞, 1, 1¼, 1⅜,1½, 1⅝, 1¾, 1⅞, 2 inches. In various embodiments the set distance can beabout within a range of between any two of the above specifieddistances.

In one embodiment the switch from high torque to low torque modes foreach of the modules (110A-F) are done simultaneously. In one embodimentthe switch is individually done for each of the modules.

In one embodiment the rate of vertical movement (in the direction ofarrow 64) of each drive socket 1010 remains constant during verticallifting (in the direction of arrow 64).

In one embodiment the rotational speed (in the direction of arrow 68) ofthe drive socket 1010 remains constant during vertical lifting (in thedirection of arrow 64).

In one embodiment a set vertical height (H_(LF1) shown in FIG. 17) thelifting fork 1410 is extended (in the direction of arrow 1402). In oneembodiment full extension of the lifting fork 1410 is determined by atiming sequence using the lifting fork hydraulic cylinder(s) 1440, suchas extension hydraulic pressure for a set period of time which can be ½,¾, 1, 1½, 2, 3, 4, and 5 seconds. In various embodiments the set periodof time can be within a range of between any two of the above setperiods of time.

In one embodiment the lifting fork 1410 remains extended until the drivesocket 1010A-F) reaches a second vertical height in the direction ofarrow 64 (H_(LF2) shown in FIG. 18) at which height the lifting fork1410 is retracted (in the direction of arrow 1404). In one embodimentfull retraction of the lifting fork 1410 is determined by a timingsequence using the lifting fork hydraulic cylinder(s) 1440, such as byretraction hydraulic pressure for a set period of time which can be ½,¾, 1, 1½, 2, 3, 4, and 5 seconds. In various embodiments the set periodof time can be within a range of between any two of the above setperiods of time.

In one embodiment rotation of the drive socket 1010 in the direction ofarrow 68 is stopped simultaneously with the start of retraction (in thedirection of arrow 1404) of the lifting fork 1410.

In one embodiment after start of retraction (in the direction of arrow1404) of the lifting fork 1410, the drive socket 1010 is sent to a homeposition for retracted vertical (in the direction of arrow 64) andretracted horizontal (in the direction of arrow 61) positioning.

In one embodiment the retraction in a vertical mode (raising drivesocket 1010 in the direction of arrow 64) is achieved before the startof retraction in a horizontal mode (in the direction of arrow 61). Inone embodiment the drive socket 1010 is not spun either in high speed orin high torque during retraction. In one embodiment retractionvertically (in the direction of arrow 64) is checked by a verticalheight sensor 1350. In one embodiment retraction horizontally (in thedirection of arrow 61) is by a pre-set time period. The horizontalradially retracted home position can be checked by a timing sequenceusing the body slide cylinders (362 and 364), such as retractionhydraulic pressure for a set period of time which can be 1, 2, 3, 4, 5,6, 7, 8, 9, and 10 seconds of retraction pressure. In variousembodiments the set period of time can be within a range of between anytwo of the above set periods of time. Fully retracted positions can becontrolled by fully retracted body slide cylinders, or by a retractioncatch, or a combination of the two. In one embodiment there can be anadjustable body retraction stop 358 (e.g., adjustment screws 359) foreach body module 140 in the retraction step.

In one embodiment the broken out riser joint 42 is removed, and theremaining riser string (lower riser joints 46 etc.) is raised until anew flange is revealed to be broken out. In one embodiment the abovespecified steps are repeated for newly revealed flange connectionbetween two riser joint sections.

In one embodiment the above specified steps are repeated until thelength of riser has been removed.

Tightening or Make Up Sequence

Various additional embodiments are described below for the make up mode.

In one embodiment (FIGS. 5 and 6) the height H to the driving tip orsocket 1010 is such that it is positioned above (giving a clearance Hcl)the maximum height of the non-tightened head of bolt 32 which will betightened by wrench 110.

Vertical positioning of driving tip or socket 1010 can be accomplishedby using vertical lifting and lowering mechanism 1300 which includeselevator 1200. Horizontal positioning of driving tip or socket 1010 canbe accomplished using adjustable sliding housing 140 and controlcylinders 362 and 364.

Risers 40 are made up of a plurality of riser sections 42, 46, etc., andtypically come in standard sizes and specifications so that bolts 32 ina non-tightened condition will be at a known maximum height.Accordingly, the minimum height H (FIGS. 5 and 6) for driving tip orsocket 1010 can be calculated relatively easily. Additionally, themaximum height of the top of wrench 400 should be below the bottom ofthe insulation found on the riser section being make up (otherwise thewrench 400 could damage the insulation). The distance between theinsulation and the riser typically is made to a specified distance andthe maximum height can be easily determined.

Driving tip or socket 1010 can be moved horizontally in the direction ofarrow 60 until driving tip or socket 1010 is directly over the head ofbolt 32.

Vertical lifting and lowering mechanism 1300 (with elevator 1400) canbegin to lower driving tip or socket 1010 downward in the direction ofarrow 63.

For tightening driving tip or socket 1010 is turned clockwise in thedirection of arrow 66.

Initially, turning in the direction of arrow 66 can be at a relativelyslow speed until driving tip or socket 1010 engages the head of bolt 32.

After engagement the speed of driving tip or socket 1010 can beincreased using the high speed/low torque driver 1200 to initiallytighten bolt 32.

As bolt 32 is tightened it will move vertically downward (in thedirection of arrow 63). To compensate for such downward movement,vertical lifting and lowering mechanism 1300 can also lower wrench 400.The amount of lowering of wrench 400 (and drive tip or socket 1010) canbe calculated based on the rotational speed with which bolt 32 is beingturned by driver tip or socket 1010. Because the pitch of bolt 32 willbe known, the amount of vertical movement can be calculated once therotational speed of bolt 32 is known. The rotational speed of bolt 32can be approximated by the nominal rotational speed of the highspeed/low torque driver 1200 (which this controls) or the low speed/hightorque driver 590 (when this controls). In this manner engagementbetween driver tip or socket 1010 can be achieved during the entiretightening process. In one embodiment a height sensor 1350 can be usedwhich tracks movement of elevator 1300 (and therefore drive tip orsocket 1010).

In one embodiment motor 1310 can be set to rotate lifting screw 1330such that lifting screw 1330 tends to move housing 1230 (and driver tipor socket 1010) more rapidly downwardly in the direction of arrow 63than bolt 32 (being tightened by tip 1010) moves downwardly. In thisembodiment, when bolt 32 does not drop as fast as lifting screw 1330attempts to move downwardly housing 1230 of high speed/low torque driver1200, the head of bolt 32 will prevent tip 1010 (and housing 1230) frombeing moved downward in the direction of arrow 63, and motor 1310 ofvertical lifting and lowering mechanism will stall based on theresistance to screw 1330 trying to pull down housing 1230 when bolt 32and tip 1010 is holding up housing 1230—at least until bolt 32 istightened enough (i.e., rotated by tip 1010) to allow tip 1010 andhousing 1230 to also move downwardly in the direction of arrow 63thereby freeing motor 1310 to again start turning screw 1330 andlowering housing 1230 and tip 1010. It is anticipated that repetitive“cycles” of starting and stalling of motor 1310 during this torquingdown sequence of bolt 32 will be seen.

In various commercially available riser constructions, the bolt 32 isnot completely threaded from its tip to its head and there exists anon-threaded portion. With these non-completely threaded bolts andrisers there will exist during a part of the tightening process wherethe entire threaded portion of bolt 32 is between the threaded portionsof the threaded portions of upper and lower riser sections 42 and 46. Atthis point the bolt 32 will freely drop an amount (approximately oneinch) until it engages the threaded portion of the lower riser section46. To address this partial free fall, driver tip or socket 1010 canhave an excess socket depth so that when bolt 32 experiences such freefall, the head of bolt 32 is still retained (albeit by an amount lessthan the free fall), but a sufficient amount so that proper engagementcan be continued during the remainder of the tightening process.Immediately, after engagement of bolt 32 with the lower riser section 44only a small amount of torque will be needed.

During the tightening of bolt 32 in the flange 47 of lower riser section46, the free fall distance of the bolt 32 could be made up by wrench 400using vertical lifting and lowering mechanism 1300 lower driving tip orsocket 1010. This can be done either by having wrench 400 lowered at afaster rate then bolt 32 is being moved downward by tightening.Alternatively, a lowering step of wrench 400 could be used wheremechanism 1300 lower wrench 400 a distance (e.g., the free fall distanceof bolt 32) while driving tip or socket 1010 is not rotating (orrotating at a very slow speed).

Typically, even after bolt 32 engages the threaded portion of flange 47of lower riser section 46, the low torque portion of wrench 400 cancontinue to tighten bolt 32 (and the high torque portion will not beneeded) until shoulder to shoulder contact is achieved between the headof bolt 32 and the flange 43 of the upper riser section 42.

In one embodiment the wrench 400 switches to high torque based on theheight of drive socket 1010. In one embodiment, when ever a high torqueportion is needed (e.g., the driving torque for bolt 32 exceeds therecommended torque for low torque driving portion), wrench 400 cantransition from the low torque to the high torque driver. In oneembodiment, wrench 400 can switch from low torque to high torque (andvice versa) as many times and as frequently as needed by bolt 32. Forexample, there may be some debris in the threaded portion of flange 43of upper riser section 42 which increases the amount of torque requiredto turn bolt 32. If this occurs then wrench 400 can transition to thehigh torque portion and turn bolt 32 until the debris is cleared atwhich time the torque required to drive bolt 32 decreases and wrench 400transitions back to the low torque driver such as until shoulder toshould contact between bolt 32 and riser section is achieved when againwrench 400 transitions to the high torque portion to complete thetightening process.

Driving tip or socket 1010 can be continued to be turned in thedirection of arrow 66 (moving bolt 32 in the direction of arrow 63)until a specified height is achieved of drive tip 1010 (such heightapproximating shoulder-to-shoulder contact between the head of bolt 32and the flange 43 of the upper riser section 42). After this point ahigher torque is expected to be required in making up bolt 32 and thehigh torque/low speed portion of wrench 400 can take over rotatingdriver tip or socket 1010 in the direction of arrow 66 thereby torquingdown bolt 32 until the desired torque is achieved.

After the desired “make up” torque on bolt 32 is achieved driver tip orsocket 1010 can be disengaged from bolt 32 where vertical lifting andlowering mechanism 1300 raises driver tip or socket 1010 (in thedirection of arrow 64) and driver tip or socket 1010 is also movedhorizontally in the direction of arrow 61 so that none of the componentsof wrench 400 will fall within a hypothetical cylinder extending fromthe outside of the flanges 43, 47 of upper and lower riser sections 42and 46. To decrease cycling time driver tip or socket 1010 can be movedhorizontally in the direction of arrow 61 shortly after it clears thehead of bolt 32 (compared to raising wrench 400 to its maximum heightbefore horizontal movement in the direction of arrow 61 is started).

After adequate clearance between riser 40 and wrench 110 is achieved(such as when torque modules 110A-F have been completely retracted), theriser sections are lowered so that a new riser section is placed onpreviously upper riser section 46 (and now riser section 46 becomes thenew lower riser section and the newly placed riser section becomes thenew upper riser section), and the making up process begins again usingthe above referenced steps.

It is expected that the entire cycle time from first starting the torquewrench 110 in the direction of arrow 60, tightening bolts 32, and movingtorque wrench out of the way and ready for the next tightening cyclewill be less than three minutes. In various embodiments the entire cycletime from the start of a tightening sequence for all six bolts on asingle flange level to completion of tightening sequence on the flangelevel is less than about 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130,140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270,280, 290, 300, 310, 320, 330, 340, 350, and/or 360 seconds. In variousembodiments a range between about any to of the above referenced timescan be used. In various embodiments these timing limits can bemaintained for greater than 5, 10, 15, 20, 30, 40, 50, 60, and moreflange levels in installing or tripping in the riser string.

Loosening or Break Out Sequence

Various additional embodiments are described below for the break outmode.

Driving tip or socket 1010 can be moved horizontally in the direction ofarrow 60 until driving tip or socket 1010 is directly over the head ofbolt 32.

Driving tip or socket 1010 can be turned in the direction of arrow 68(i.e., counter-clockwise) for loosening. Vertical lifting and loweringmechanism 1300 can lower driving tip or socket 1010 downward in thedirection of arrow 63.

Initially, turning in the direction of arrow 68 can be at a relativelyslow speed until driving tip or socket 1010 engages the head of bolt 32.Typically, after engagement a high torque will be needed to break outshoulder to shoulder contact between the head of bolt 32 and the flange43 of the upper riser section 42.

In one embodiment the high torque/low speed portion of wrench 400 isprevented from operating until a desired minimum height of driving tipor socket head 1010 is achieved. This embodiment can resist strippingout of the head of bolt 32. In this embodiment the driving tip or socket1010 can be turned slowly at a low torque until the desired minimumdepth of engagement between driving tip or socket 1010 and bolt 32 isachieved.

With adequate engagement between driving tip or socket 1010 and bolt 32,the high torque/low speed portion of wrench 400 can be used to “breakout” bolt 32 from its shoulder to shoulder engagement. Typically a hightorque mode is required for this initial “break out” During the hightorque mode wrench 400 rotates driving tip or socket 1010 in thedirection of arrow 68 (moving bolt 32 in the direction of arrow 64)until shoulder-to-shoulder contact is relieved/removed between the headof bolt 32 and the flange 43 of the upper riser section 42.

Shortly after breaking out the shoulder to shoulder contact, it isexpected that a lower torque will be required to continue turning bolt32 in the direction of arrow 68, and the high speed/low torque driver1200 can take over loosening of bolt 32. Additionally, the highspeed/low torque driver 1200 can turn bolt 32 rotationally fastercompared to the high torque/low speed portion of wrench 400.

As bolt 32 is loosened it will move vertically upward (in the directionof arrow 64). To compensate for such upward movement, vertical liftingand lowering mechanism 1300 can also raise wrench 400. The amount ofraising of wrench 400 (and driver tip or socket 1010) can be calculatedbased on the rotational speed with which bolt 32 is being turned bydriver tip or socket 1010. Because the pitch of bolt 32 will be known,the amount of vertical movement can be calculated once the rotationalspeed of bolt 32 is known. In this manner engagement between driver tipor socket 1010 and bolt 32 can be maintained during the entire looseningprocess.

In various commercially available riser constructions, the bolt 32 isnot completely threaded from its tip to its head and there exists anon-threaded portion. With these non-completely threaded bolts andrisers there will exist during a part of the loosening process where theentire threaded portion of bolt 32 is between the threaded portions ofthe threaded portions of upper and lower riser sections 42 and 46. Atthis point the bolt 32 will “freely spin” and no longer rise. In oneembodiment the “break out” portion is completed once the “free spin”condition is reached because bolt 32 no longer threadably connects upperand lower riser sections. However, if bolt 32 is left in the “free spin”state its threads can be damaged when riser section 42 is moved andrelocated. Accordingly, it is preferred that bolt 32 is continued to beunloosed until it threads into upper riser section 42 so that thethreads of bolt 32 will be protected. To address the “free spin”condition of bolt 32, lifting fork 1400 can be used to lift bolt 32until bolt 32 starts threading into the threaded portion of the upperriser section 42. Lifting fork 1400 can move in the direction of arrow1402 until fork 1400 engages the head of bolt 32. Lifting fork 1400 andwrench 1400 can continue to be raised by vertical lifting and loweringmechanism 1200 until the threaded portion of bolt 32 begins to engagethe threaded portion of the upper riser section 42. To address thispartial free spinning state of bolt 32 and re-engagement with the upperriser section, driver tip or socket can be slowed to avoid crossthreading the upper riser section 42. Immediately, after engagement ofbolt 32 with the upper riser section 42 only a small amount of torquewill be needed.

Driver tip or socket 1010 continues to loosen bolt 32 until a desiredposition for a “state of breakout” is obtained for bolt 32. After thedesired state of breakout is for bolt 32 is achieved driver tip orsocket 1010 is disengaged from bolt 32 where vertical lifting andlowering mechanism 1300 raises driver tip or socket 1010 in thedirection of arrow 64 and driver tip or socket 1010 is also retracted ormoved horizontally in the direction of arrow 61 so that none of thecomponents of wrench 400 will fall within a hypothetical cylinderextending from the outside of the flanges 43, 47 of upper and lowerriser sections 42 and 46.

After clearance is achieved from the upper riser section 42 is removedand lower riser section raised so that a new riser section is seenconnected to previously lower riser section 46 (and now riser section 46becomes the new upper riser section and the newly raised riser sectionbecomes the new lower riser section), and the breaking out processbegins again using the above referenced steps.

It is expected that the entire cycle time from first starting the torquewrench 110 in the direction of arrow 60, loosening bolt 32, and movingtorque wrench out of the way and ready for the next loosening cycle willbe less than sixty seconds.

In one embodiment motor 1310 can be set to rotate lifting screw 1330 ata slower rate such that lifting screw 1330 tends to move housing 1230(of high speed/low torque driver 1200) upwardly a little more slowly inthe direction of arrow 64 than bolt 32 (being loosened by tip 1010)tends to move upwardly tip 1010 and housing 1230. In this embodiment,when bolt 32 rises faster than lifting screw 1330 attempts to move uphousing 1230, the head of bolt 32 will push tip 1010 (and housing 1230)upward in the direction of arrow 64, tending to cause screw 1330 to alsorotate faster, turning and speeding up motor 1310 to catch up to theheight of bolt 32. In this embodiment it is anticipated that thethreading of screw 1330 will not lock up with the interconnectingthreading for housing 1230.

In one embodiment motor screw 1330 can be turned at a rotational speedwhich will approximate the vertical lift of bolt 32. If screw 1330 isactually turning faster and causing driver tip or socket 1010 to moveupwardly (in the direction of arrow 64) faster than bolt 32 is moving,driver tip or socket 1010 has enough excess socket depth compared to thehead of bolt 32 that driver tip socket 1010 will maintain adequatecontact with the head of bolt 32 during the entire upward movement ofbolt 32. For example, the head of bolt 32 may have a nominal head depthof 3⅜ inches so that when driver tip or socket 1010 is fully placed onthe head of bolt 32 3⅜ inches of head will be inside of driver tip orsocket 1010. If during the lifting cycle screw 1330 raises housing 1230(and driver tip or socket 1010) an extra 1 or 2 inches compared to theheight in which bolt 32 is raised, 2⅜ or 1⅜ inches of the head of bolt32 will still remain in driver tip or socket 1010.

It is expected that the entire cycle time from first starting the torquewrench 110 in the direction of arrow 60, loosening bolt 32, and movingtorque wrench out of the way and ready for the next loosening cycle willbe less than sixty seconds. In various embodiments the entire cycle timefrom the start of a loosening sequence for all six bolts on a singleflange level to completion of loosening sequence on such flange level isless than about 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140,150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280,290, 300, 310, 320, 330, 340, 350, and/or 360 seconds. In variousembodiments a range between about any to of the above referenced timescan be used. In various embodiments these timing limits can bemaintained for greater than 5, 10, 15, 20, 30, 40, 50, 60, and moreflange levels in retrieving tripping out the riser string.

Initial Engagement Between Driver and Head of Bolt

After driver or socket head 1010 has been placed directly over bolt 32such that the centerline of rotation of driver or socket 1010 lines upwith the center of rotation of bolt 32, there may still be anon-alignment between the driving portions of driver or socket 1010 andthe driven portions of the head of bolt 32. There is a risk (albeitsmall) that rotating at such a high speed when initial contact betweendriver or socket 1010 and the head of bolt 32 will damage one or both ifthe driving surfaces of both are not properly aligned during firstcontact.

Accordingly, in one embodiment an alignment sequence can be used tofacilitate initial engagement with driver or socket head 1010 and bolt32 where the effective rotational speed of driver or socket 1010 issubstantially reduced. Normal high speed rotational speed of highspeed/low torque driver 1200 can exceed about 100 revolutions perminute, e.g., about 100, 105, 110, 115, 120, 125, 130, 135, 140, and 150revolutions per minute. The alignment sequence can include highspeed/low torque driver 1200 turning driver or socket 1010 at arelatively low speed until proper engage is achieved. This low alignmentspeed can be less than an average of 50, 45, 40, 35, 30, 35, 30, 25, 20,15, 10, 9, 8, 7, 6, 5, 4, 3, 2, and/or 1 revolution per minute.

The slower alignment speed with high speed/low torque driver 1200 can beachieved by controlling the speed of motor 1210, such as by placingmotor 1210 in a low speed phase.

Additionally, the slower alignment speed with high speed/low torquedriver 1200 can be achieved by only intermittently supplying pressurizedhydraulic fluid to motor 1210 (or supplying pressurized hydraulic fluidin spurts). Another option is to make motor 1210 a variable speed motor.Such an engagement mode can be maintained until a proper engagementbetween driver or socket 1010 with bolt 32.

Proper engagement can be determined using a variety of means such as:(a) calculating a vertical movement of driver or socket head 1010 and/ormeasuring resistance to additional vertical dropping of driver or sockethead 1010 when driver or socket head is restrained from additionaldropping by the bolt head; (b) measuring backpressure in the hydraulicpressure of to motor 1210; and/or (c) measuring resistance to verticaldropping of driver or socket head 1010 (and connected wrench 400).

In one embodiment the effective vertical height of the head of bolt 32is 3⅜ inches. In one embodiment a vertical drop of driver or socket 1010a specified amount (e.g., 1, 1½, 2, 2½, 3, 3½, and/or 4 inches)(or 10,20, 30, 40, 50, 60, 70, 80, 90, 95, and 100 percent or the depth of thehead of bolt 32) over the head of bolt 32 is determined to be effectiveengagement and high speed/low torque driver 1200 can increase to itsnormal high rotational speed mode.

In one embodiment changes in the back pressure to motor 1210 can be usedto determined proper engagement. It is anticipated that resistance tothe turning of driver or socket 1010 will vary before proper engagement(where the driving faces of both driver or socket 1010 and the drivenfaces of the head of bolt 32) meet compared to driver or socket merelyspinning on top of the head of bolt 32. This difference in back pressurecan be used to determine proper engagement.

In one embodiment changes in backpressure to motor 1310 of verticallifting and lowering mechanism can be used to determine properengagement. If proper engagement is not obtained between driver orsocket 1010 and bolt 32 (where the driving faces of both driver orsocket 1010 and the driven faces of the head of bolt 32), bolt 32 willresist downward movement of wrench 400 and increase resistance tovertical lifting and lowering mechanism 1300, which can cause motor 1310to stall. This difference in back pressure can be used to determineproper engagement.

In one embodiment one or more (or all three) of the above means can beused to determine proper engagement.

In various embodiments the above referenced initial engage steps can beused in both the make up and break out sequences.

Schematic Diagrams for Components and Hydraulic Flow

FIGS. 45 through 47 include schematic diagrams of the hydraulic circuitscontrolling the high torque driver system 590, low torque driver 1200,vertical lifting and lowering mechanism 1300, sliding system for slidinghousing 140 (cylinders/pistons 362 and 364), and lifting fork mechanism1400.

FIGS. 45 (make up) and 46 (break out) show fluid flow and control forthe low speed/high torque portion 590. In one embodiment, automaticreciprocation of piston 740 (distinguished from manual reciprocation ofprior art wrenches) is obtained. Basically, piston 740 can beautomatically reciprocated between extended and retracted states inside(e.g., between first interior wall 712 and second interior wall 712 ofhydraulic cylinder 700).

In one embodiment cylinder 700 can contain interior extension 713 andretraction 715 hydraulic ports. Cylinder 700 can have an interiorchamber length L (between first 712 and second 714 interior walls), andpiston 740 can have a width D corresponding to the interior chamber sizeof cylinder 700. In one embodiment fluid source lines 713 and 715 can belocated on side walls 712 and 714. In other embodiments fluid sourcelines 713 and 715 can be spaced apart a desired length (such as betweeninterior walls 712 and 714).

In the start of the extension/advance mode for piston 740 and rod 750(i.e., movement in the direction of arrow 774) piston 740 can be locatedto the rear of cylinder 700 (FIG. 34). Hydraulic fluid can flow intofrom port 713 causing piston 740 to move in the direction of arrow 774.As piston 740 moves (in the direction of arrow 774) past port 722, port722 will see hydraulic pressure causing the flow direction mechanismschematically shown in the figures to switch flow from fluid source line713 to fluid source line 715 causing the piston 740 and rode 750 toenter the retraction mode and move in the direction of arrow 772.

The retraction mode can be controlled on a timing basis which can beflow through port 715 for a set period of time which can be 1, 2, 3, 4,5, 6, 7, 8, 9, and/or 10 seconds of retraction pressure. In variousembodiments the set period of time can be between any two of thespecified periods of time.

During make up the above steps of entering the extension/advance modeand retraction mode continue until piston 740 stalls from reaching aspecified back-pressure. This is preferably the backpressure whichcauses a desired torque on bolt 32.

During break out the above steps of entering the extension/advance modeand retraction mode can continue for a specified number of strokes.

For extension in the high torque cylinder 700, pressure is sent to theextension port 713 causing piston 740 to move in the direction of arrow774 until pressure is read in the pilot port 722 (this will occur whenthe piston 740 passes up the pilot port 722 to see the hydraulic fluidinside the cylinder 710). Once the pilot port 722 sees pressure thesystem reverses hydraulic fluid flow to now send fluid through theretraction port 715 for a set period of time which can be 1, 2, 3, 4, 5,6, 7, 8, 9, and 10 seconds of retraction pressure. Flow throughretraction port 715 will cause piston 740 to move in the direction ofarrow 772.

On make-up this process (alternating stroking of piston 740 and rod 750in the directions of arrows 774 and 772) is repeated until apre-specified pressure is reached on the extension port with the pilotport having a reduced pressure (low to zero).

On break-out this process (alternating stroking of piston 740 and rod750 in the directions of arrows 774 and 772) can be repeated for the setnumber of cycles.

Overall Side View in of Steps in Making Up (Tripping in) MultipleSections of a Riser

FIGS. 48 through 57 schematically show various steps in making upindividual joints of a riser 40.

FIG. 48 is a schematic side view of the step of making up a riser 40string of lowering (in the direction of arrow 63) a second riser section45 onto a first riser section 46 where the first riser section 46 alongwith the rest of the riser 40 string is supported by the spider 50.

FIG. 49 is a close up side view of where the second riser section 45 hasbeen placed on top of the first riser section 46 showing a plurality ofriser bolts 32A-F ready to be tightened with the spider 50 supportingthe riser 40 string and a plurality of torque modules 110A-F are locatedin their home position.

FIG. 50 is a side view schematically indicating that the plurality oftorque modules 110A-F have extended (radially in the direction of arrow60) are making up the plurality of riser bolts 32A-F while the riserstring 40 is being supported by the spider 50.

FIG. 51 is a side view schematically indicating that the plurality oftorque modules 110A-F have completed the make up of the plurality ofriser bolts 32A-F and such modules are retracting (radially in thedirection of arrow 61) to their home position.

FIG. 52 shows the now made up joint (flanges 43 and 47) between thesecond 42 and first 46 riser sections is being lowered (in the directionof arrow 63) by the rig lifting elevator 22 after the spider 50 has beenretracted (in the direction of arrows 54).

FIG. 53 is a side view of the now made up joint (flanges 43 and 47)between the second 42 and first 46 riser sections is being lowered (inthe direction of arrow 63) by the rig lifting elevator 22 (whichsupports the riser 40 string by attachment to the upper flange 45 of thesecond riser section 42) after the spider 50 has been retracted.

FIG. 54 is a side view of the elevator 22 supporting the riser string 20by the upper flange 45 of the second riser section 42 and located thisupper flange 45 in the spider 50 for support. Arrows 52 schematicallyindicate that the spider 50 has closed to support riser string 40 bysupporting upper flange 45.

FIG. 55 is a close up view of the elevator 22 supporting the riserstring 40 by the upper flange 45 of the second riser section 42 andhaving placed the upper flange 45 on the spider 50 for support.

FIG. 56 is a close up view of the elevator 22 being removed(schematically indicated by arrow 64) from the upper flange 45 of thesecond riser section 42. Riser string 40 (along with second risersection 42) is supported by spider 50.

FIG. 57 is a perspective view of all six torque modules 110A-F in theirhome positions and set up in the break out mode on spider 50. Radialarrows 60 and 61 schematically indicate extension and retraction of eachof the modules. Upper and lower arrows 62 and 63 schematically indicatedupward movement and lower movement of individual drive sockets 1010A-Ffor each of the modules.

Rotational Counter

In one embodiment a rotational counter can be used to count the number(and possibly the direction) of revolutions of driver tip or socket 1010after driver tip or socket 1010 engages the head of bolt 32. Because thepitch of the threads on bolt 32 are known the distance of verticalmovement of bolt 32 can be determined. This distance of verticalmovement of bolt 32 can be made up by vertical lifting and loweringmechanism 1300 in combination with height sensor 1350. The counter ofrotations of bolt 32 can be for one or more portions of the verticalmovement of bolt 32. Different portions can be analyzed because of thestep where bolt 32 freely spins between the upper and lower flanges (43and 47) and/or drops between these two upper and lower flanges (43 and47).

In one embodiment a rotational counter can be used to count the number(and possibly the direction) of revolutions of vertical lifting andlowering screw 1330 (and/or motor 1310) to calculate the verticalmovement of driver tip or socket 1010. Because the pitch of the threadson screw 1330 are known the distance of vertical movement of bolthousing 1200 (and tip or socket 1010) can be determined. This distanceof vertical movement can be used to control lifting and loweringmechanism 1300 during various steps in the various sequences.

LIST OF REFERENCE NUMERALS

The following is a list of reference numerals used in the presentapplication:

Reference Numeral Description: 10 perspective view of preferredembodiment 20 rig 22 lifting elevator for rig 32 bolt 40 riser 42 risersection 43 flange 44 floatation/insulation material for riser section 45upper flange 46 riser section 47 flange 48 projection of cylinder 49 gap50 spider 52 arrow (extension) 54 arrow (retraction) 60 arrow 62 arrow64 arrow 66 arrow 68 arrow 70 arrow 80 control panel/hydraulic fluidsource 100 wrench system 110 wrench 140 sliding housing 142 top 144bottom 146 front 148 rear 150 side wall 152 side wall 154 foot connector155 foot connector 156 foot connector 157 foot connector 160 brace 170brace 180 brace 190 tracks 192 track 194 track 196 track 198 track 300base 310 top 320 bottom 330 front 331 radial tabs 332 connecting pins334 connecting pins 340 rear 350 guide system 352 guide shaft 354 guideshaft 356 front plate 357 extension adjusters 358 rear plate 359retraction adjusters 360 positioning system for base 362 hydrauliccylinder and piston 363 rod 364 hydraulic cylinder and piston 3654 rod400 wrench 406 wrench body 410 top 420 bottom 440 first end 450 secondend 452 arrows 460 top opening for driver 470 bottom opening for driver480 opening for cylinder pivot rod 490 opening for vertical lifting andlowering screw 498 bore for reaction bar 500 reaction bar 510 first end520 second end 590 high torque driver 600 drive gear 610 plurality ofangular teeth 620 opening in drive gear for drive pin 700 reciprocatingcylinder 702 arrows 706 arrows 708 arrows 710 cylinder 712 firstinterior wall 713 extension port 714 second interior wall 715 retractionport 720 cylinder yoke 722 pressure port 730 opening for pivot pin 734pivot pin 740 piston 750 piston rod 760 tip for piston rod 770 arrow 772arrow 774 arrow 778 pivot 800 first drive plate 810 second drive plate820 drive plate extension 825 spacer 830 bore in first drive plate fordrive gear 840 bore in second drive plate for drive gear 850 bore infirst drive plate for piston rod tip 852 bore in second drive plate forpiston rod tip 860 bore in first drive plate for drive pawl 870 bore insecond drive plate for drive pawl 880 first bushing 881 opening 882second bushing 883 opening 884 plurality of connectors 900 drive pawl910 pivot tips for drive pawl 920 drive pawl biasing member (e.g.,springs) 1000 driver 1010 driver tip 1012 axis of rotation 1020 openingfor head of bolt 1030 depth of opening 1040 driver shaft 1042 first end1044 second end 1046 cross sectional shape 1050 high speed connectionarea 1052 plurality of teeth for high speed connector 1200 highspeed/low torque driver 1210 motor 1220 belt 1222 tension pulleys 1230housing 1232 first end 1234 second end 1236 top 1238 bottom 1240 openingfor vertical lifting and lowering screw 1242 threaded area for verticallifting and lowering screw 1250 plurality of tracks 1252 track 1254track 1256 track 1258 track 1300 vertical lifting and lowering mechanism1310 motor 1330 vertical lifting and lowering screw 1332 arrow 1334arrow 1350 height sensor 1360 moving indicator for sensor 1370 depth toknown origin/level/standard 1400 screw lifting mechanism 1402 arrow 1404arrow 1410 lifting fork 1420 plate 1430 track 1432 track 1440 drivinghydraulic cylinder and piston or pair of driving cylinders and pistons

It will be understood that each of the elements described above, or twoor more together may also find a useful application in other types ofmethods differing from the type described above. Without furtheranalysis, the foregoing will so fully reveal the gist of the presentinvention that others can, by applying current knowledge, readily adaptit for various applications without omitting features that, from thestandpoint of prior art, fairly constitute essential characteristics ofthe generic or specific aspects of this invention set forth in theappended claims. The foregoing embodiments are presented by way ofexample only; the scope of the present invention is to be limited onlyby the following claims.

1. An improved multi-bolt or nut torque wrench system for installing orremoving a plurality of threaded bolt or nut members on a riser, thesystem comprising: (a) a plurality of torque stations, each torquestation including: (i) a wrench body that includes first and second endportions, and a drive head on the first end portion of the body; (ii) ahigh torque wrench operatively connected to the drive head for rotatinga threaded bolt or nut member at a first rotational speed under ahigh-torque condition; (iii) a low torque wrench operatively connectedto the drive head for rotating the threaded bolt or nut member at asecond rotational speed that is a higher rotational speed than therotational speed of the high torque wrench; (iv) a horizontalpositioning mechanism for moving the drive head in a generallyhorizontal direction; (v) a vertical positioning mechanism for movingthe drive head in a generally vertical direction, which the verticalpositioning mechanism can vertically position the drive head independentfrom operation of the high torque and low torque wrenches; (b) a sourceof pressurized fluid that drives the plurality of torque stations; and(c) a controller that controls the plurality of torque stations,including the high torque wrenches, the low torque wrenches, thehorizontal positioning mechanism, and the vertical positioningmechanisms such that the plurality of drive heads engage theirrespective bolt or nut members.
 2. The improved wrench system of claim1, wherein six torque stations are radially spaced about a circle andthe six stations simultaneously engage their respective bolt or nutmembers.
 3. The improved wrench of claim 1, wherein each torque stationincludes a reaction member, and each vertical positioning mechanismcauses its respective drive head to move in a generally verticaldirection relative to its respective reaction member.
 4. The method ofclaim 1, wherein each torque station includes an extendable andretractable bolt lifting fork, wherein in the extended condition eachbolt lifting fork can vertically move a bolt to which its respectivedrive head is attached in the event the bolt enters a freely spinningcondition.
 5. A method of making up a riser string from a rig,comprising the following steps: (a) providing a plurality of torquestations, each torque station including: (i) a wrench body that includesfirst and second end portions, and a drive head on the first end portionof the body; (ii) a high torque wrench operatively connected to thedrive head for rotating a threaded bolt member at a first rotationalspeed under a high-torque condition; (iii) a low torque wrenchoperatively connected to the drive head for rotating the threaded boltmember at a second rotational speed that is a higher rotational speedthan the rotational speed of the high torque wrench; (iv) a horizontalpositioning mechanism for moving the drive head in a generallyhorizontal direction; and (v) a vertical positioning mechanism formoving the drive head in a generally vertical direction, which thevertical positioning mechanism can vertically position the drive headindependent from operation of the high torque and low torque wrenches;(b) providing a source of pressurized fluid for driving the plurality oftorque stations including the high torque wrenches, low torque wrenches,horizontal positioning mechanisms, and vertical positioning mechanisms;and (c) providing a controller that controls the plurality of torquestations, including the high torque wrenches, the low torque wrenches,the horizontal positioning mechanisms, and the vertical positioningmechanisms; (d) supporting a riser string on a drilling rig or platform,the riser string including a plurality of joints of riser sections; (e)placing an additional riser section above the riser string, additionalriser section including a plurality of riser threaded bolt members; (f)the controller causing the plurality of drive heads to each engage oneof the plurality of riser threaded bolt members; (g) the controllercausing the plurality of drive heads to spin down their respectivelyengaged riser threaded bolt members, wherein, during the spin downprocess, the respective high and/or low torque wrenches turning theirrespective drive heads; (h) after being spun down, each of the pluralityof riser threaded bolt members being torqued down to a desired torque bythe respectively engaged high torque wrenches; (i) the controllercausing the plurality of drive heads to disengage the plurality of riserthreaded bolt members, and providing clearance for another section ofriser to be made up to the riser string; and (j) lowering the riserstring a distance so that a new section of riser can be made up to theriser string.
 6. The method of claim 5, wherein during step “f” the lowtorque wrenches cause the plurality of drive heads to engage theplurality of threaded bolt members, and the low torque wrenches arehydraulically relaxed for a predetermined period of time, and betweensteps “f” and “g” the high torque motors cause the plurality of driveheads to rotate during a positioning movement, during step g the lowtorque motors cause the plurality of drive heads to spin down theirrespectively engaged riser threaded bolt members.
 7. The method of claim5, wherein step “h” is performed only after step “g” is completed foreach of the plurality of riser threaded bolt members of a particularriser section.
 8. The method of claim 5, wherein in step “c”, thecontroller is a computer.
 9. The method of claim 5, wherein in step “c”,the controller automatically controls the high torque wrench, low torquewrench, horizontal positioning mechanism, and vertical positioningmechanism.
 10. The method of claim 5, wherein in step “a” 6 torquestations are provided which are radially spaced apart in about 60 degreeincrements about a circle.
 11. The method of claim 5, wherein in step“f” each of the plurality of riser threaded bolt members aresimultaneously engaged.
 12. The method of claim 5, wherein before andduring step “f” the rotational speed of the plurality of drive heads isslower than the rotational speeds of the plurality of drive heads instep “g.”
 13. The method of claim 5, wherein during step “f” therotational speed of the plurality of drive heads is slower than therotational speeds of the plurality of drive heads in step “g.”
 14. Themethod of claim 5, wherein the fluid flow is switched automaticallyduring both steps “g” and “h.”
 15. A method of making up a riser stringfrom a rig, comprising the following steps: (a) providing a plurality oftorque stations, each torque station including: (i) a wrench body thatincludes first and second end portions, and a drive head on the firstend portion of the body; (ii) a high torque wrench operatively connectedto the drive head for rotating a threaded bolt member at a firstrotational speed under a high-torque condition; (iii) a low torquewrench operatively connected to the drive head for rotating the threadedbolt member at a second rotational speed that is a higher rotationalspeed than the rotational speed of the high torque wrench; (iv) ahorizontal positioning mechanism for moving the drive head in agenerally horizontal direction; and (v) a vertical positioning mechanismfor moving the drive head in a generally vertical direction; (b)providing a source of pressurized fluid for driving the plurality oftorque stations including the high torque wrenches, low torque wrenches,horizontal positioning mechanisms, and vertical positioning mechanisms;and (c) providing a controller that controls the plurality of torquestations, including the high torque wrenches, the low torque wrenches,the horizontal positioning mechanisms, and the vertical positioningmechanisms; (d) supporting a riser string on a drilling rig or platform,the riser string including a plurality of joints of riser sections; (e)placing an additional riser section above the riser string, additionalriser section including a plurality of riser threaded bolt members; (f)the controller causing the plurality of drive heads to each engage oneof the plurality of riser threaded bolt members; (g) the controllercausing the plurality of drive heads to spin down their respectivelyengaged riser threaded bolt members, wherein, during the spin downprocess, the respective high and/or low torque wrenches turning theirrespective drive heads; (h) after being spun down, each of the pluralityof riser threaded bolt members being torqued down to a desired torque bythe respectively engaged high torque wrenches; (i) the controllercausing the plurality of drive heads to disengage the plurality of riserthreaded bolt members, and providing clearance for another section ofriser to be made up to the riser string; and (j) lowering the riserstring a distance so that a new section of riser can be made up to theriser string, wherein during step “g” the each of the verticalpositioning mechanisms attempt to lower their respective drive head at arate faster than the downward rate of the respective riser threaded boltmember being spun down.
 16. A method of breaking out a riser string froma rig, comprising the following steps: (a) providing a plurality oftorque stations, each torque station including: (i) a wrench body thatincludes first and second end portions, and a drive head on the firstend portion of the body; (ii) a high torque wrench operatively connectedto the drive head for rotating a threaded bolt member at a firstrotational speed under a high-torque condition; (iii) a low torquewrench operatively connected to the drive head for rotating the threadedbolt member at a second rotational speed that is a higher rotationalspeed than the rotational speed of the high torque wrench; (iv) ahorizontal positioning mechanism for moving the drive head in agenerally horizontal direction; and (v) a vertical positioning mechanismfor moving the drive head in a generally vertical direction, which thevertical positioning mechanism can vertically position the drive headindependent from operation of the high torque and low torque wrenches;(b) providing a source of pressurized fluid for driving the plurality oftorque stations including the high torque wrenches, low torque wrenches,horizontal positioning mechanisms, and vertical positioning mechanisms;and (c) providing a controller that controls the plurality of torquestations, including the high torque wrenches, the low torque wrenches,the horizontal positioning mechanisms, and the vertical positioningmechanisms; (d) supporting a riser string on a drilling rig or platform,the riser string including a plurality of joints of riser sections; (e)the controller causing the plurality of drive heads to each engage oneof the plurality of riser threaded bolt members; (f) the controllercausing each of the drive heads to break out their respectively engagedriser threaded bolt member; (g) causing the plurality of drive heads tospin up their respectively engaged riser threaded bolt members, wherein,during the spin up process, the respective high and/or low torquewrenches turning their respective drive heads; (h) the controllercausing the plurality of drive heads to disengage the plurality of riserthreaded bolt members, and providing clearance for another section ofriser to be broken out of the riser string; (i) removing and retrievinga riser joint section of the riser string; and (j) raising the riserstring a distance so that a new riser joint section can be broken out,removed, and retrieved.
 17. The method of claim 16, wherein in steps “a”through “j” are repeated until the entire riser string is removed andretrieved.
 18. The method of claim 16, wherein step “g” is performedonly after step “f” is completed for each of the plurality of riserthreaded bolt members of a particular riser section.
 19. The method ofclaim 16, wherein in step “a” 6 torque stations are provided which areradially spaced apart in about 60 degree increments about a circle. 20.The method of claim 16, wherein in step “e” each of the plurality ofriser threaded bolt members are simultaneously engaged.
 21. The methodof claim 16, wherein each torque station includes a reaction member, andeach vertical positioning mechanism causes its respective drive head tomove in a generally vertical direction relative to its respectivereaction member.
 22. A method of breaking out a riser string from a rig,comprising the following steps: (a) providing a plurality of torquestations, each torque station including: (i) a wrench body that includesfirst and second end portions, and a drive head on the first end portionof the body; (ii) a high torque wrench operatively connected to thedrive head for rotating a threaded bolt member at a first rotationalspeed under a high-torque condition; (iii) a low torque wrenchoperatively connected to the drive head for rotating the threaded boltmember at a second rotational speed that is a higher rotational speedthan the rotational speed of the high torque wrench; (iv) a horizontalpositioning mechanism for moving the drive head in a generallyhorizontal direction; and (v) a vertical positioning mechanism formoving the drive head in a generally vertical direction; (b) providing asource of pressurized fluid for driving the plurality of torque stationsincluding the high torque wrenches, low torque wrenches, horizontalpositioning mechanisms, and vertical positioning mechanisms; and (c)providing a controller that controls the plurality of torque stations,including the high torque wrenches, the low torque wrenches, thehorizontal positioning mechanisms, and the vertical positioningmechanisms; (d) supporting a riser string on a drilling rig or platform,the riser string including a plurality of joints of riser sections; (e)the controller causing the plurality of drive heads to each engage oneof the plurality of riser threaded bolt members; (f) the controllercausing each of the drive heads to break out their respectively engagedriser threaded bolt member; (g) causing the plurality of drive heads tospin up their respectively engaged riser threaded bolt members, wherein,during the spin up process, the respective high and/or low torquewrenches turning their respective drive heads; (h) the controllercausing the plurality of drive heads to disengage the plurality of riserthreaded bolt members, and providing clearance for another section ofriser to be broken out of the riser string; (i) removing and retrievinga riser joint section of the riser string; and (j) raising the riserstring a distance so that a new riser joint section can be broken out,removed, and retrieved, wherein in step “a” each torque station includesan extendable and retractable bolt lifting fork, wherein in the extendedcondition each bolt lifting fork can vertically move a bolt to which itsrespective drive head is attached in the event the bolt enters a freelyspinning condition, and wherein during step “g” each threaded riser boltenters a free spin mode and is lifted by one of the extendable andretractable bolt lifting forks.